Klaxon Turbo 2, Turbo 3, ES-2, ES-3, ES-4 Assembly Guide
KLAXON SIGNALS
KLAXON
ES SIREN MAST
ASSEMBLY
GUIDELINES
Klaxon Signals
Wrigley St
Oldham
Lancs
OL4 1HW
Phone: ++ 44 (0) 161 287 5555
Fax: ++ 44 (0) 161 287 5511
Email: sales@klaxonsignals.com
SG001a Issue 1 Dec 06
KLAXON SIGNALS
CONTENTS
1. SIREN HORN CABLE(S) MANUFACTURE......................................... 2
1.1 Cable Specification............................................................................2
2. SIREN CABLE CONSTRUCTION TABLES......................................... 3
2.1 Turbo 2 (2 Horn / 1 Cable).............................................................. 3
2.2 Turbo 3 (3 Horn / 2 Cable).............................................................. 4
2.3 ES-2 (6 Horn / 1 Cable).................................................................. 5
2.4 ES-3 (12 Horn / 1 Cable)................................................................ 5
2.4 ES-3 (12 Horn / 1 Cable)................................................................ 6
2.5 ES-4 (18 Horn / 2 Cable)................................................................ 7
3. CABLE JUNCTION BOX ASSEMBLY INSTRUCTIONS ..................... 9
3.1 PURCHASED COMPONENTS....................................................10
4. MAST ASSEMBLY INSTRUCTIONS................................................. 11
5. HORN ARRAY DIMENSIONS & WEIGHT......................................... 22
6. HORN ASSEMBLY TESTING............................................................ 22
7. STANDARD SIREN MAST INFORMATION ...................................... 23
7.1 Mast Lengths, Weights and Number of Horns.............................. 23
7.2 Mast Fixing Bolts..........................................................................23
7.3 Mast Base Construction ............................................................... 23
7.4 Standard Mast Drawings.............................................................. 24
7.4.1 3 Metre Mast (18-185938) ..................................................... 25
7.4.2 4.5 Metre Mast (18-185939) .................................................. 26
7.4.3 6 Metre Mast (18-185940) ..................................................... 27
7.4.4 12 Metre Support Mast (18-185941)......................................28
7.4.5 12 Metre Support Mast Mounting Flange 1 (18-185942) .......29
7.4.6 12 Metre Support Mast Mounting Flange 2 (18-185943) .......30
7.4.7 Turbo 2/3 & ES2 Siren Horn Cable Box Bracket (18-186209)31
7.4.8 ES3 & ES4 Siren Horn Cable Box Bracket (18-186210)........ 32
SG001a Issue 1 1 of 32 Apr 07
KLAXON SIGNALS
1. SIREN HORN CABLE(S) MANUFACTURE
1. Identify the siren type for which the cable is to be constructed and use
the tables appended to the bottom of this section for connection
information.
2. Determine the length of the cable required and cut cable to length.
(Length of mast + 1 metre + the length of the longest conductor stated
in the siren type table).
3. Cut the protective sheath back to the length of the longest required
conductor specified in the siren type table and remove.
4. Cut the respective conductors to the lengths specified in the siren
type table and remove.
5. If a single cable is being used then loom the conductors as specified
in the siren type table.
6. Crimp the connector plug onto the individual conductors and then
insert the crimped connectors into the connector housings.
Note: When the wires are inserted into the connectors the orientation
of odd or even numbered wires to the left hand or the right hand side
does not matter as long as they are all orientated in the same
manner.
1.1 Cable Specification
Siren Type Cable Required
Turbo 2, Turbo 3 4 Core 1.5mm2 YY Cable
ES-2, ES-3, ES-4 25 Core 1.5mm2 YY Cable
SG001a Issue 1 2 of 32 Apr 07
KLAXON SIGNALS
2. SIREN CABLE CONSTRUCTION TABLES
Dependent on the number of horns associated with the siren one or two
cables will be required. The tables below identify specific requirements
based on the siren type.
2.1 Turbo 2 (2 Horn / 1 Cable)
Length of individual wires from
Horn Number
& Amplifier
1/ Amp 1 1 & 2 240
2/ Amp 1
Note: Cable to be used is a four core cable with three cores being
numerically identified and the remaining core being the green/yellow earth
core.
GREEN/YELLOW
Wire
Identification
Numbers
3 &
Turbo 2 Horn Arrangement
the point where the outer sheath
of the multi-core cable is
terminated.
(mm)
240
Horn 1Horn 2
SG001a Issue 1 3 of 32 Apr 07
KLAXON SIGNALS
2.2 Turbo 3 (3 Horn / 2 Cable)
CABLE 1
Length of individual wires from
Horn Number
& Amplifier
Wire
Identification
Numbers
the point where the outer sheath
of the multi-core cable is
terminated.
(mm)
1/Amp 1 1 & 2 240
2/Amp 1
GREEN/YELLOW
3 &
880
CABLE 2
Length of individual wires from
Horn Number
& Amplifier
Wire
Identification
Numbers
the point where the outer sheath
of the multi-core cable is
terminated.
(mm)
3/Amp 1 1 & 2 240
Note: Cable to be used is a four core cable with three cores being
numerically identified and the remaining core being the green/yellow earth
core.
Horn 1
Horn 2
Horn 3
Turbo 3 Unidirectional Horn Arrangement
SG001a Issue 1 4 of 32 Apr 07
KLAXON SIGNALS
2.3 ES-2 (6 Horn / 1 Cable)
CABLE 1
Length of individual wires from
Horn Number
& Amplifier
Wire
Identification
Numbers
the point where the outer sheath
of the multi-core cable is
terminated.
(mm)
1/Amp 1 1 & 2 240 (Loom in cable loom 1)
2/Amp 1 3 & 4 880 (Loom in cable loom 1)
3/Amp 1 5 & 6 1520 (Loom in cable loom 1)
4/Amp 2 11 & 12 240 (Loom in cable loom 2)
5/Amp 2 13 & 14 880 (Loom in cable loom 2)
15 & 16
6/Amp 2
(All unused
1520 (Loom in cable loom 2)
wires)
Note: Cable to be used is a 25 core cable with 24 cores being numerically
identified and the remaining core being the green/yellow earth core.
Horn 4
Horn 5
Horn 6
Horn 1
Horn 2
Horn 3
ES-2 Horn Arrangement
SG001a Issue 1 5 of 32 Apr 07
KLAXON SIGNALS
2.4 ES-3 (12 Horn / 1 Cable)
CABLE 1
Length of individual wires from
Horn Number
& Amplifier
Wire
Identification
Numbers
the point where the outer sheath
of the multi-core cable is
terminated.
(mm)
1/Amp 1 1 & 2 240 (Loom in cable loom 1)
2/Amp 1 3 & 4 880 (Loom in cable loom 1)
3/Amp 1 5 & 6 1520 (Loom in cable loom 1)
4/Amp 3 7 & 8 2160 (Loom in cable loom 1)
5/Amp 3 9 & 10 2800 (Loom in cable loom 1)
6/Amp 3 11 & 12 3440 (Loom in cable loom 1)
7/Amp 2 13 & 14 240 (Loom in cable loom 2)
8/Amp 2 15 & 16 880 (Loom in cable loom 2)
9/Amp 2 17 & 18 1520 (Loom in cable loom 2)
10/Amp 4 19 & 20 2160 (Loom in cable loom 2)
11/Amp 4 21 & 22 2800 (Loom in cable loom 2)
23 & 24
12/Amp 4
(Plus unused
3440 (Loom in cable loom 2)
wires
Horn 07
Horn 08
Horn 09
Horn 10
Horn 11
Horn 12
Horn 01
Horn 02
Horn 03
Horn 04
Horn 05
Horn 06
ES-3 Horn Arrangement
SG001a Issue 1 6 of 32 Apr 07
KLAXON SIGNALS
2.5 ES-4 (18 Horn / 2 Cable)
CABLE 1
Length of individual wires from
Horn Number
& Amplifier
Wire
Identification
Numbers
the point where the outer sheath
of the multi-core cable is
1/Amp 1 1 & 2 240
2/Amp 1 3 & 4 880
3/Amp 1 5 & 6 1520
4/Amp 3 7 & 8 2160
5/Amp 3 9 & 10 2800
6/Amp 3 11 & 12 3440
7/Amp 5 13 & 14 4080
8/Amp 5 15 & 16 4720
17 & 18
9/Amp 5
(Plus unused
wires
CABLE 2
Length of individual wires from
Horn Number
& Amplifier
Wire
Identification
Numbers
the point where the outer sheath
of the multi-core cable is
1/Amp 2 1 & 2 240
2/Amp 2 3 & 4 880
3/Amp 2 5 & 6 1520
4/Amp 4 7 & 8 2160
5/Amp 4 9 & 10 2800
6/Amp 4 11 & 12 3440
7/Amp 6 13 & 14 4080
8/Amp 6 15 & 16 4720
17 & 18
9/Amp 6
(Plus unused
wires
terminated.
(mm)
5360
terminated.
(mm)
5360
SG001a Issue 1 7 of 32 Apr 07
KLAXON SIGNALS
Horn 10
Horn 11
Horn 12
Horn 13
Horn 14
Horn 15
Horn 01
Horn 02
Horn 03
Horn 04
Horn 05
Horn 06
Horn 16
Horn 07
Horn 17
Horn 08
Horn 18
Horn 09
ES-4 Horn Arrangement
SG001a Issue 1 8 of 32 Apr 07
KLAXON SIGNALS
3. CABLE JUNCTION BOX ASSEMBLY INSTRUCTIONS
1. Select the correct enclosure for use as a cable junction box and
associated mounting bracket.
Siren Type Enclosure
Turbo 2 190mm x 190mmx 100mm Small
Turbo 3 190mm x 190mmx 100mm Small
ES-2 190mm x 190mmx 100mm Small
ES-3 250mm x 200mmx 100mm Large
ES-4 250mm x 200mmx 100mm Large
2. Cut a length of top hat section DIN rail to fit the enclosure and fit
using screws and nuts supplied with the enclosure.
3. Drill holes in enclosure for the attachment of cable glands. The
number and type are as specified in the table below. For a one cable
siren assembly two cable glands will be required in the side face of
the unit either side of the DIN rail strip. For a two cable assembly two
further cable glands would be required on the opposite face of the
enclosure to the first two cable glands.
Siren Type
No of
Glands
Gland Size
(mm)
Turbo 2 2 9.0 15.5 4
Turbo 3 4 9.0 15.5 6
ES-2 2 21.0 29.0 12
ES-3 2 21.0 29.0 24
ES-4 4 21.0 29.0 36
Enclosure Mounting
Bracket
Hole Size
(mm)
Connectors
No of
SG001a Issue 1 9 of 32 Apr 07
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