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
LED MODULES
The LED modules are available as “flashing” and “stationary” versions. 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® 925 or 700 series relay flasher). The flashing modules will have "Cycleflash"
as the standard pattern. Flash patterns can be changed by shorting the 2-pin header, J1 as shown
in Figure 3, momentarily then releasing. Table 1 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 seconds and releasing.
Directional Module Flash Pattern - Table 1
Flash Pattern Description
Cycle Flash Cycles through various patterns @ 70 fpm
Steady-Burn Steady-Burn
Five Flash Five Pulses per flash @ 70 fpm
Quad Flash Four Pulses per flash @ 70 fpm
Triple Flash Three Pulses per flash @ 70 fpm
Double Flash Two Pulses per flash @ 70 fpm
Fast Double Flash Two Pulses per flash @ 85 fpm
NFPA Four Pulses, 70% Duty Cycle @ 75 fpm
Quad Pop Flash Four Pulses per flash ( 3 equal, 1 extended) @ 70 fpm
Triple Pop Flash Three Pulses per flash ( 2 equal, 1 extended) @ 70 fpm
PCB
Momentarily short and release
to change patterns
J1
FIGURE 3
5
Maintenance
Make sure power is disconnected to the lightbar before servicing. Refer to Figure 4. To remove
the top lens, remove the 4 screws around the perimeter. Place a blade screwdriver into the
notches at the front of the top lens and twist. This should lift the lens up enough to remove the top
lens by hand.
If an LED assembly is not working, refer to the troubleshooting section. If it needs to be removed,
disconnect power to the module by pulling apart the red quick connect terminal and unscrewing the
black ground lead. Remove the 2 sheet metal screws. Halogen assemblies are removed in the
same manner.
Before reassembling the top lens, make sure the gasket is properly seated.
T16320 - #8 SCREW
T16321 - #8 WASHER
SCREWDRIVER NOTCH
FOR OPENING LENSES
XP9500 TOP LENS
REMOVAL PROCESS
Figure 4
6
Troubleshooting
All XP9500 lightbars 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.
LED MODULE
TROUBLESHOOTING GUIDE
Note: LED modules must be replaced as a module. There are no user serviceable parts.
PROBLEM
LED directional
module not
operating when
powered.
Lamp or LED
module does not
come on when it
should (based on
controller function)
QUESTIONS
N/A
Are the
controller
panel LED
indicators
functioning
properly?
Yes
POSSIBLE CAUSE
a. Bad power/ground
connection.
b. Defective module.
a. Bad lamp or defective
LED module
SOLUTION
a. Fix connection.
b. Replace module.
a. Replace lamp or LED module
No
b. Defective wiring
connection
a. Control box is damaged
7
b. Repair connection
a. Return to Code 3
5
4
3
6
2
1
S27000-S27003
Ref. Part Number Description
1 S23995-S23998 3-up LED/Reflector Assembly
2 S24148 LED Lighthead Mounting Plate
3 T08873 Lens Spacer
4 See Table 2 Aluminum Frame
5 T51001 Lower Lens
6 S23987-S23994 6-up LED/Reflector Assembly
Table 2
T16301 Mounting Frame (1 Pod)
T16302 Mounting Frame (2 Pod)
T16303 Mounting Frame (3 Pod)
T16304 Mounting Frame (4 Pod)
T16305 Mounting Frame (5 Pod)
T16306 Mounting Frame (6 Pod)
T16307 Mounting Frame (7 Pod)
Other 3up LED lighthead assemblies available
S23957-S23962 Optix LED lighthead assembly
Call factory OLP Single lighthead assembly
Call factory OLP Dual lighthead assembly
Other LED lighthead assemblies available
S27012-S27019 12-up LED/Reflector assembly
S27004-S27011 8u-p LED/Reflector assembly
S23963-S23986 6u-p Optix LED lighthead assembly
S23939-S23946 6-up OLP dual lighthead assembly
Parts not shown
T51011 Clear upper lens
T08874 Right side endcap
T08875 Left side endcap
S27180 35 Watt Alley/Front light
S24186 55 Watt Alley/Front light
T16320 Lens Screw
8
T16321 Lens Screw washer
T16323 Frame/Lens gasket
T01215 #8 Screw-module mounting
T02946 #8 Screw-lower lens to frame
XP 9500 OVERALL DIMENSIONS
DESCRIPTION PODS LENGTH DEPTH HEIGHT
XP9512 1 12.500 7.375 3.000
XP9525 2 25.062 7.375 3.000
XP9538 3 37.625 7.375 3.000
XP9550 4 50.188 7.375 3.000
XP9563 5 62.750 7.375 3.000
XP9575 6 75.313 7.375 3.000
XP9588 7 87.875 7.375 3.000
9
NOTES:11NOTES:
10
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. guarantees all parts and components, except the halogen
lamps, for a period of 1 year, LED lighthead modules to a period of 5 years (unless otherwise expressed) from the date of purchase or delivery, whichever is later. Units demonstrated to be defective within the warranty period will be repaired or replaced at the factory
service center at no cost.
Use of a lamp or other electrical load of a wattage higher than installed or recommended by the factory, or use of inappropriate or inadequate wiring or circuit protection
causes this warranty to become void. Failure or destruction of the product resulting from
abuse or unusual use and/or accidents is not covered by this warranty. Use of non-Code 3
components and assemblies may cause damage to the system and/or personal injury, and
voids all warranties on Code 3 systems and components.
Code 3 shall in no way be liable for other damages including consequential, indirect or
special damages whether loss is due to negligence or breach of warranty.
CODE 3 MAKES NO OTHER EXPRESS OR IMPLIED WARRANTY INCLUDING,
WITHOUT LIMITATION, WARRANTIES OF FITNESS OR MERCHANTABILITY, WITH
RESPECT TO THIS PRODUCT.
PRODUCT RETURNS
In order to provide you with faster service, if you are going to return a product 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. Write the RGA number clearly on the
package near the mailing label. Be sure you use sufficient packing materials to avoid
damage to the product being returned while in transit.
*Code 3 reserves the right to repair or replace product at its discretion. Code 3 assumes no responsibility
or liability for expenses incurred for the removal and/or reinstallation of products requiring service and/or repair.
St. Louis, Missouri 63114-2029—USA
Ph. (314) 426-2700 Fax (314) 426-1337
Code 3® is a registered trademark of Code 3, Inc.
Revision 0, 8/2007 - Instruction Book Part No. T16326
10986 N. Warson Road
©2004 Code 3, Inc. Printed in USA
Code 3®, Inc.
www.code3pse.com
12
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