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.
Page 2
Introduction
The SOLEX™ (Patent-Pending) Light bar Features the truly unique, SIRIS™ (Patent-Pending) Technology which constitutes a quantum leap forward
in signal brightness far exceeding the intensity and quality of any system. The low prole and aerodynamic lines reduce air drag, which results in
fuel savings and stability at high speeds. The SOLEX light bar also has an extruded internal frame that is 2X stronger, shock-resistant polycarbonate
lenses with an intermolded solar barrier, and warning signals that exceed SAE standards.
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 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.
WARNING!
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.
Installation & Mounting
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!
Page 3
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, Options, and Specications
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.
Fusing Considerations
The SOLEX™ 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 output on
the Central Controller board is protected against over current and over heating with automatically resetting output devices.
Dim Operation
The SOLEX 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 SIRIS™ light heads will operate in a reduced
power 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
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.
Page 4
WARNING!
This Product contains high intensity LED powered 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: For lightbars equipped with programmable light head pairs refer to the following:
If the lightbar has all single color light heads, please see supplement T16406 (800Series
Software).
If the lightbar has any multi-color light heads, please see supplement T54006 (950Series
Software).
STEP 1
Select the desired 3-Level mode to program by applying +power to the appropriate wire in the 16 conductor cable.
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.
3-LEVEL MODES OF OPERATION
MODE NUMBERWIRES ACTIVATED
L1GRN/BLK (LEVEL-1)
L2WHT/BLK
L1 + L2GRN/BLK & WHT/BLK (LEVEL-2)
L3RED/BLK
L1 + L3GRN/BLK & RED/BLK
L2 + L3WHT/BLK & RED/BLK
L1 + L2 + L3GRN/BLK, WHT/BLK, & RED/BLK (LEVEL-3)
Table 1
STEP 2
Observe the ashing pattern operation and determine which pattern is in operation. 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
Make sure +12v is only applied to the function you are trying to program - otherwise program function will not
operate.
Page 5
Lighting
Factory Default
Level
L1L2L3
Factory Default
Level 2
1515
Fast Alternating Quad Flash
1626Alternating Two Flash
1737
Alternating Single Flash
1848Fast Picket Fence Quad Flash
1959Slow Picket Fence Quad Flash
20610Alternating Quad Flash
21711Slow Alternating Six Flash
22812Alternating Six Flash
23913Variable Rate Even/Odd Flash
241014Alternating Quad Flash 75 FPM (NFPA)
Factory Default
Level 1
11115
Fast Alternating Quad Flash (Rear Only)
21216Fast Even/Odd Quad Flash (Rear Only)
31317Alternating Quad Flash (Rear Only)
41418Alternating Six Flash (Rear Only)
51519Variable Rate Even/Odd Head Flash (Rear Only)
61620Fast Alternating Quad Flash (Front Only)
71721Fast Even/Odd Quad Flash (Front Only)
81822Alternating Quad Flash (Front Only)
91923Alternating Six Flash (Front Only)
102024Variable Rate Even/Odd Head Flash (Front Only)
Factory Default
Level 3
11211
Cycle Flash (cycles through multiple ash patterns)
The Pattern Select wire is the BLK/RED wire as noted above in the sixteen conductor light bar control cable and is activated by
momentarily touching the wire to +power.
Page 6
FLASH PATTERN SELECTION NOTES:
*
(See Table 1B) When the ArrowStik® Left and ArrowStik Right wires are both connected to +power, the Center-Out ArrowStik function is acti
vated.
** (See Table 1B) When the Pattern Select wire is connected to +power and all other inputs are off, test mode is enabled to exercise all outputs in
sequence until +power is removed from the wire.
The Steady Burn function for both the Take Down and Alley lights will always override the Wig/Wag Flash function.
The Cruise Light function is mutually exclusive with all other functions. If any other input has +power applied, the Cruise Lights will be turned off.
Light bars with software T116XXV6 or greater, T117XXV6 or greater or T118XXV2 or greater or T514XXV0 or greater can operate the Cruise Light
Function and the Dim Function together. The Dim Function has no affect on the Cruise Lights.
Steady Burn Setting
The SOLEX's™ Steady Burn feature allows up to two (2) of the light bar's SIRIS™ light heads to be designated to operate in Steady Burn mode.
The Steady Burn SIRIS light heads are always connected to connectors P9 & P10.
The Steady Burn outputs are enabled by the 3-Level control inputs. The SOLEX may be congured so that Steady Burn SIRIS light heads are on
when either L1, L2 or L3 are active (JP1 position); when L2 or L3 are active (JP2 position) or just when L3 is active (JP3 position). Simply move the
jumper to the appropriate location (JP1, JP2 or JP3). Refer to the detail in Figure 1.
Page 7
ArrowStik® Modules
Selecting the ArrowStik Pattern
The Central Controller is designed to offer user selectable trafc directing and trafc warning ash patterns. Each of the ArrowStik functions (LEFT,
CENTER-OUT, RIGHT or FLASH) can be programmed individually for unique patterns and ash rates. This allows the greatest exibility when
controlling the various light bar congurations available. The light bar can be ordered with a 5, 6, 7 or 8 lighthead conguration. The light bar
will come from the factory with the Building Fast pattern as the default for LEFT, CENTER-OUT and RIGHT. The default pattern for FLASH is the
Standard Flash. If it is desired to change the pattern for any of the functions, follow the programming procedure below.
STEP 1:
Power-up the light bar. Select the ArrowStik function that you wish to program (LEFT, CENTER-OUT, RIGHT or FLASH).
Make sure +12v is only applied to the function you are trying to program - otherwise program function will not
operate.
STEP 2:
Continue applying power to the wire from Step 1. Refer to Table 2 for the available ash patterns.
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 2 will begin to ash. The new pattern is automatically
stored each time.
Notice that for the LEFT, CENTER-OUT and RIGHT functions there are four pattern choices (Building, Building with 3 Flash for the end lightheads,
Traveling Ball with 3 Flash for the end lightheads, and Build/Collapse) and three speeds (Fast, Medium and Slow). There are a total of twelve
possible selections for each function and then you return to the top selection.
For the FLASH function there are nine trafc warning patterns available. Flash patterns marked with an asterisk “*” can be selected in Fast, Medium
or Slow ash rate.
NOTE: To restore the Factory Default ArrowStik Flash Patterns, hold the BLK/RED wire to +power for ~four
seconds.
STEP 3:
Repeat steps 1 through 2 for the other ArrowStik functions as desired.
Patterns with the * have a fast,
medium, or slow speed.
Page 8
Take Down and Alley Flash
Selecting Flash Patterns:
The Take Down and Alley Lights can be programmed to ash at different rates.
STEP 1:
Power-up the light bar. Select the Take Down Flash Mode (BLK) or the Alley Flash Mode (BLU/WHT) by applying +power to the appropriate wire. .
NOTE: Make sure +12v is only applied to the function you are trying to program - otherwise program function will
not operate.
STEP 2:
Observe the ash pattern and determine which pattern is in operation (see Table 3). This table shows the available ash patterns. Once the ash
pattern has been determined, proceed to Step 3. NOTE: The default ash pattern for Take Down and Alley Lights is Medium
Single 115FPM.
STEP 3:
Scroll to the next pattern by momentarily holding the BLK/RED wire to +power for ~one (1) second. The light bar will stop ashing when the wire
is connected to +power. Release the wire and the next pattern as listed in Table 3 will begin to ash. The new pattern is automatically stored each
time. NOTE: To restore the Factory Default Take Down and Alley Flash Patterns, hold the BLK/RED wire to +power
for ~four (4) seconds.
TAKE DOWN AND ALLEY FLASH PATTERNS
PATTERN NUMBERPATTERN DESCRIP-
TION
1FAST QUAD 80FPM
2SLOW QUAD 60FPM
3FAST SINGLE 375FPM
4MEDIUM SINGLE 115FPM
5SLOW SINGLE 60FPM
6FAST DOUBLE 115FPM
7SLOW DOUBLE 60FPM
8FAST SIX 80FPM
9SLOW SIX 60FPM
10VARIABLE RATE SINGLE
11NFPA QUAD 75FPM
12CYCLE FLASH
Table 3
Maintenance
Lens Cleaning
Use plain water and a soft cloth, or Code 3® lens polish and a very soft paper towel or facial tissue. Plastic scratches easily, as a result, cleaning is
recommended only when necessary (about every six months). Do not subject the lenses to car washes that use brushes, as these will scratch the
lenses.
Lens Removal
With a Phillips screwdriver, remove the cap attachment screws (with neoprene washers). Insert a small screwdriver blade (or coin) into the small slot
a the corner of the lens cap and twist the screwdriver to lift the cap. Then gently lift the cap off. When nished carefully replace the cap making sure
the lens gasket is not misplaced, then replace the cap mounting screws making sure the neoprene washers are in place.
Light Head Removal
Unplug the SIRIS™ light head's power wire/wires from the light bar's wiring harness. Then with a 1/4" Hex Bit Driver, remove the #8 X .270" 6 Lobe
Hex Washer Head Screws that attach the light head mounting bracket to the light bar. The takedowns and alleys require decoupling mated quickslide terminals (be sure to pull on the terminals and not the wires).
Page 9
SOLEX™ - EXPLODED VIEW
FIGURE 2
Page 10
Parts List
(Reference numbers identify items shown in Figure 2)
Ref No. Description Part No.
1 Outboard Lower Lens Green T51440
Clear T51441
Red T51442
Blue T51443
Amber T51444
2 Center Lower Lens Green T51450
All-Light (No Grill) Clear T51451
Red T51452
Blue T51453
Amber T51454
3 Outboard Upper Cap Clear T51501
Red T51502
Blue T51503
Amber T51504
Black T51505
4 Center Upper Cap Clear T51511
Red T51512
Blue T51513
Amber T51514
Black T51515
5 Lens Mtg Screw W Neoprene Washer - 0.625" Long T51179
6 Lens Mtg Screw W Neoprene Washer - 1.500" Long T51439
7 Outboard Lower Mtg Plate T51550
8 Center Lower Mtg Plate with Support T51553
9 Center Upper Mtg Plate T51558
15 9-UP Light Head: Red, Blue, Amber, White, Green
18-UP Light Head Dual Color: Red/Blue, Red/Amber, Blue/Amber, Red/White, Blue/White, Amber/White
16 3-UP Take Down or Alley Light Head
17 6-UP Take Down Head
18 PCB, with ArrowStik
PCB, with ArrowStik
PCB, with ArrowStik
® control T11564
® control for dual color T55490
® sister control for dual color T55491
CALL FACTORY
Page 11
Any disassembly of any of the SIRIS™ light heads will result in loss of warranty coverage on the
equipment.
WARNING!
Troubleshooting
All SOLEX™ Light bars are thoroughly tested prior to shipment. However, should you encounter a problem during installation or during the life of the
product, follow the guide below for information on repair and troubleshooting. Additional information may be obtained from the factory technical help
line at 314-996-2800.
SIRIS™ LIGHT HEAD
TROUBLESHOOTING
Note: LED light heads must be replaced as a module. There are no user serviceable parts. Warranty is void if
module is disassembled
PROBLEMQUESTIONSPOSSIBLE CAUSESOLUTION
SIRIS Front Module
not operating
Are all heads out
in front or in back,
and not just a
single module out?
YesNoa. Front and/or Rear Cut Function powered
a. Defective module
b. Cable/Connector unplugged
SIRIS Corner Module
has one head out.NAa. Defective module
b. Cable/Connector unplugged
Cruise Lights do not
operateNAa. No power on Cruise wire
b. Another Central Controller Function is on
Notes:
a. Remove power (turn off) Front and/or Rear Cut
a. Replace module
b. Check cable & connector
a. Replace module
b. Check cable & connector
a. Connect Cruise wire to switch
b. Turn off other functions
Page 12
WARRANTY
This product was tested and found to be operational at the time of manufacture. Provided this product is
installed and operated in accordance with the manufacturer's recommendations, Code 3®, Inc. warrants all parts
and components (with the exception of all incandescent and halogen bulbs) of the product to be free of defects in
material and workmanship for a period of one (1) year and SIRIS™ led light heads for a period of ve (5) years
from the date of purchase. This Warranty excludes normal wear & tear. Units demonstrated to be defective within
the warranty period will be repaired or replaced at the factory service center at no cost. Code 3, Inc. will return
the repaired product with transportation cost prepaid. Code 3, Inc. assumes no liability for expenses incurred in
the packaging, handling, and shipping of the product to the Factory Technical Service Department for repair. For
in-warranty product return authorization, questions regarding product warranty coverage or questions regarding
out-of-warranty repair quotes, contact the Factory Technical Service Department.
This Warranty is void if, in the judgment of Code 3, Inc. (1) an attempt has been made to repair the light
head, and/or (2) the product has been used with inappropriate or inadequate wiring or circuit protection, and/or
(3) the product has failed as a result of abuse or unusual use and/or accidents.
CODE 3, INC. SHALL IN NO WAY BE LIABLE FOR ANY OTHER DAMAGES RELATING TO THE PRODUCT INCLUDING BUT NOT LIMITED TO CONSEQUENTIAL,
INCIDENTAL, INDIRECT OR SPECIAL DAMAGES OR LOST PROFITS OR REVENUE;
NOR ANY EXPENSES INCURRED IN THE REMOVAL AND/OR RE-INSTALLATION OF
PRODUCTS REQUIRING SERVICE AND/OR REPAIR.
EXCEPT AS SET FORTH ABOVE, CODE 3, INC. MAKES NO OTHER EXPRESS
OR IMPLIED WARRANTIES WHATSOEVER, INCLUDING, WITHOUT LIMITATION,
WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, WITH RESPECT TO THIS PRODUCT.
PRODUCT RETURNS
If a product must be returned for repair or replacement*, please contact our factory to obtain a Return
Goods Authorization Number (RGA number) before you ship the product to Code 3®, Inc. Write the RGA number
clearly on the package near the mailing label. Be sure you use sufcient packing materials to avoid damage to
the product being returned while in transit.
*Code 3®, Inc. reserves the right to repair or replace at its discretion. Code 3®, Inc. assumes no responsibility or liability for
expenses incurred for the removal and /or reinstallation of products requiring service and/or repair.; nor for the packaging, handling, and
shipping: nor for the handling of products returned to sender after the service has been rendered.
Code 3® is a registered trademark of Code 3, Inc.
For Technical Support / Service, please call 314-996-2800.