Code 3 XP 9500 User Manual
INSTALLATION
& OPERATION
MANUAL
XP 9500 FLUSH-MOUNT LIGHTBAR
FLUSH-MOUNT LIGHTBAR
IMPORTANT:
XP 9500
Contents:
Introduction ............................................................. 2
Unpacking & Pre-Installation................................... 2
Installation & Mounting............................................ 3
Wiring Instructions ................................................... 4
LED Warning Devices ............................................. 4
Maintenance............................................................ 6
Troubleshooting....................................................... 7
Parts List ................................................................. 8
Dimensions ............................................................. 9
Notes..................................................................... 10
Warranty................................................................ 12
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 XP9500 is an LED lightbar that contains a series of polycarbonate “pods” mounted to a strong
aluminum extrusion. Angled lights in each pod project light to the intersections while forward facing
lights provide a strong signal straight ahead. The PriZmTM LED lightheads provide a high intensity
warning signal while drawing very little current. It is only 3" high and 7 ½” deep. Alley lights and
forward clear lights round out the options for the XP 9500. Properly configured, the XP 9500
meets all SAE, California Title 13, KKK and NFPA specifications.
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
!
WARNING!
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.
Unpacking & Pre-Installation
Carefully remove the lightbar and place it on a flat surface, taking care not to scratch the lenses.
Examine the unit for transit damage. Report any damage to the carrier and keep the shipping box.
Standard lightbars are built to operate on 12 volt D.C. negative ground vehicles. If you have an
electrical system other than this 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 ground and the other wires to
+12VDC (an automotive battery is preferable for this test). A battery charger may be used, but
please note that some electronic options may not operate normally when powered by a battery
charger. If problems occur, at this point, contact the factory.
2
Installation & Mounting
Select the desired mounting location for the lightbar. This product is attached with 3/8" carriage
bolts whose centerlines are 2" below the top of the lightbar (Figure 1).
Locate the bolts along the back of the lightbar. The number of mounting bolts varies with the
length of the lightbar. Place a mounting bolt near each end of the frame. Space additional bolts
evenly across the remaining length. Locate 7/16" diameter clearance holes on the vehicle to work
with the bolt locations. Locate for easy access from the inside of the vehicle. Locate and drill a
minimum 3/4” diameter hole for the control cable exiting as shown in Figure 2 below. Insure the
cable jacket cannot be cut by sharp edges.
Route the cable and the bolts into their respective holes. Attach the washers and nuts to the bolts
from the inside of the vehicle. Apply caulk to all bolts and wires at the point of entry.
MO U NT ING AS SE M BLY /HARD W AR E F OR XP 9500
UPPER LENS
T06732 - STEP BO LT 3/8-16 X 1.5"
2.0
1.2
T06533 - 3/8 LOCK WA SH ER
FIGURE 1
T06551 - 3/8 HEX NUT
LOWER LENS
FRAME
AMBULANCE
SHEET METAL
STANDARD CABLE HOLE LOCATIONS FOR XP9500 FROM CENTERLINE OF BAR
C
L
C
L
6 9/32"
4 POD
C
L
6 9/32"
2 POD1 POD 3 POD
C
L
T01578 - 3/8 FLAT WASH ER
C
L
5 POD
C
L
6 9/32"
6 POD
C
L
7 POD
FIGURE 2
3
Wiring Instructions
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
!
WARNING!
Always refer to the wire tag attached to the lightbar cable to match lightbar functions with colored
wire. Several items may be controlled by the same wire. Extend all control wires to switching
device and make appropriate connections. The black ground wire must be securely attached to the
vehicle chassis to provide reliable grounding.
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.
LED Warning Devices
WARNING!
!
LED 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.
Minimum fuse size calculation:
1.5 x (number of 6/8/12-up modules being fused) + .5 x (number of 3-up modules being fused)
Example:
XP9500 lightbar with 7 forward facing 6-up modules and 16 angled and end facing 3-up modules
Minimum fuse requirement for single fuse: (1.5 x 7) + (.5 x 16) = 18.5A minimum
This Product contains high intensity LED devices. To prevent eye damage, DO NOT stare
into light beam at close range.
Note:
Each 35 Watt halogen lamp requires 3A fusing. Each 55 Watt halogen lamp requires 5A fusing.
4
Loading...