Star Headlight & Lantern 2500 User Manual

INSTALLATION AND INSTRUCTION MANUAL

PLITSTR341 REV F 8/4/11

!

When mounting your lightbar, please be sure to keep any radio frequency
sensitive equipment at least 20” from the bar and power cable(s). This is
especially critical in lightbars utilizing strobes. Our strobe power supplies
have been designed to limit RFI emissions, but certain very sensitive
equipment may still be affected. Symptoms may include, but are not
limited to, sporadic operation and degraded performance. Star Headlight
& Lantern Co., Inc. cannot assume any responsibility for any radio
frequency induced malfunction or damage to any radios, sirens, lightbars,
or any other equipment mounted within 20” of a strobe lightbar. Any
antennae mounted in the proximity of the lightbar may cause your radio to
suffer the aforementioned results.

PLEASE NOTE: THE DIRECT MOUNT IS THE STANDARD
MOUNT INCLUDED WITH THE LIGHTBAR.
THE HOOK MOUNTS MUST BE USED ON ALL POLICE AND/
OR OTHER EMERGENCY VEHICLES!!!
THE HOOK MOUNTS ARE SOLD SEPARATELY. THEY ARE
NOT INCLUDED WITH EACH LIGHTBAR. THEY MUST BE
ORDERED SEPARATELY. SEE THE ACCOMPANYING
HOOK MOUNT MANUAL FOR A COMPLETE LIST OF
AVAILABLE MOUNTS AND KNOWN VEHICLE
APPLICATIONS.

I

t is the sole responsibility of the owner to ensure the lightbar is
mounted securely. Check your light every time you enter the
vehicle to ensure that it is mounted securely. The manufacturer
assumes no responsibility for the secure mounting of this light.

-i-

Please Note: These instructions are provided as a general guideline only. Specific
mounting, wiring, and/or weather-sealing may be necessary and are the sole
responsibility of the installer. Star Headlight & Lantern Co., Inc. assumes no
responsibility for the integrity of the installation for this or any of its products.

WARNINGS i

QUICK-INSTALL WIRING GUIDE 1-2

Table of Contents

MOUNTING INSTRUCTIONS 3

(For Mounting see Mounting Bracket Manual)

WIRING INSTRUCTIONS 3-6

Direct Wiring Guide 3-4
Electrical Connections 5
Wire Functions 6

PATTERN PROGRAMMING 7-10

Strobe Pack Flash Patterns 7
LED Flash Patterns 8-10

PARTS 11-12

SWITCHES 13

TROUBLESHOOTING 14-16

WARRANTY 17

SERVICE 17

Due to continuous product improvements, we must reserve the right to change any specifications and information,
contained in this manual at any time without notice. Star Headlight & Lantern Co., Inc. makes no warranty of any
kind with regard to this manual, including, but not limited to, the implied warranties of merchantability and fitness
for a particular purpose. Star Headlight & Lantern Co., Inc. shall not be liable for errors contained herein or for
incidental or consequential damages in connection with the furnishing, performance, or use of this manual.

-ii-

NOTICE

Terminal

Terminal

Terminal

Terminal

Terminal Terminal

Block

Block

BlockBlock

A

P271-RAZOR

B

CONNECTED

Wire Harness for Bars Without Stop/Tail/Turn Lights

P271-TOWBAR Layout 1

CONNECTED

Terminal

Terminal

Terminal Terminal

Wire Harness for Bars with Incandescent STT Lights

Block

Block

BlockBloc k

QUICK-INSTALL WIRING GUIDE

P271-TOWBAR Layout 2

Wire Harness for Bars With LED STT Lights

Please Note: If your lightbar has an LED or incandescent traffic director in it, there will also be a separate bundled 9-conductor cable specifically for that function.

CONNECTED

TerminalTerminal

TO BASE

Terminal

Terminal

TerminalTerminal

Block

Block

BlockBlock

1

2

3

4

5

6

7

8

9

10

11

12

13

14

TO BASE

Terminal

Terminal

TerminalTerminal

A

B

TO BASE

Color AWG Function

1

Blue 18 Driver side Alley

2

White w/Blue 18 Intersection Clearing Lights

3

White w/Yellow 18 Front Corner

4

Orange w/Yellow 18 Front Outboard

5

Brown w/Yellow 22 Front Inboard and Ends

6

Red 14 Power

7

Red w/Green 22 Pattern Select

8

Purple 22 High/Low Power (Ground for Low)

9

Green w/Yellow 18 Front Takedowns

10

Red w/Black 18 AUX

11

White w/Brown 18 Front Pursuit

12

Green w/Red 18 Rear Center or TD Warn

13

Brown w/Red 22 Rear Inboard or TD Left

12

Orange w/Red 22 Rear Outboard or TD Right

1

White w/Red 18 Rear Corner (rear ICL)

2

Yellow w/Black 18 Cruise

3

White w/Black 18 Alley w/Flash

4

Gray 18 Passenger Alley

Black 10 Ground (Battery Negative)

Bare 18 Shield/Drain (Battery Negative)

Color AWG Function

Light Blue 16 Driver Side Alley Light

Orange 14

Yellow 16 Left Stop Light

Green 16 Right Stop Light

White/Orange 14 Work Lights

Brown 18 Tail Lights/I.D. Lights

Red 14 Strobe Power

Red/White 14 Power for Optional Components

Red/Green 22 Strobe Pattern Select

Black/Green 22 Strobe Head Select 1

White/Green 22 Strobe Head Select 2

Gray 16 Passenger Side Alley Light

Black 10

Bare 18

Color AWG Function

1 OPEN

2 OPEN

3 OPEN

4 Blue OPEN or Driver Alley or Steady Burn Alley

5 Orange 16 Front LEDs

6 W hite w/Orange 14 Rear Work Lights

7 Red 14 Strobe Power

8 Red w/White 14 Rear LEDs

9 Red w/Green 22 Pattern Select

10 Black w/Green 22 Strobe Control 1 or OPEN

11 W hite w/Green 22 Strobe Control 2 or OPEN

12 Gray 16 OPEN or Passenger Alley

1 Yellow 16 Left (Driver) Turn Signal

2 Di ode Red 6” Wire

3 OPEN

4 Green 16 Right (Passenger) Turn Signal

5 Di ode Red 6” Wire

6 OPEN

7 Brown 18 Tail Lights

8 Diode Red 6” Wire/Power

BLACK 10 Ground (Battery Negative)

BARE 18 Shield/Drain (Battery Negative)

Rotators

Ground (Battery Negative)

Shield/Drain (Battery Negative)

-1-

LED BARS

Orange

w/Yellow

e

t

i

w

h

o

l

l

W

e

Y

/

w

Blue

Red w/Green Stripe:

W

h

w/

i

te

R

ed

Orange

w/Red

STROBE BARS

1

e

t

i

h

w

W

o

l

l

e

Y

/

w

Brown

Brown

w/Yellow

w/Yellow

Red:

Main LEDs/Strobe Power

Purple:

High Power/Low Power
Pattern Select

Black:

Ground

Bare Wire:

Drain/Shield (connect to Ground)

Brown

Brown

w/Red

w/Red

2

Brown w/Yellow

Typical 46" Lightbar Layouts

Green

Green

w/Yellow

w/Yellow

{

White w/Brown:
(Pursuit Mode)

Green

Green

w/Red

w/Red

Green w/Yellow or

White w/Brown: (Pursuit Mode)

Brown

w/Yellow

Brown
w/Red

Brown w/Yellow

{

3

Brown

w/Yellow

Brown
w/Red

Orange

w/Yellow

Orange

w/Red

W

w

h

/

i

Y

t

e

e

l

l

o

w

Gray

e

t

i

d

h

e

W

R

/

w

4

W

h

w

i

t

e

/

Y

e

l

l

o

w

White

w/Black

(or Blue)

W

h

i

t

e

w

/

R

e

Brown w/Red Brown w/Red

d

4 1

3

2

Green w/Red

Green w/Yellow or

White w/Brown: (Pursuit Mode)

FRONT TAKEDOWN

Orange

w/Yellow

e

t

i

w

h

o

l

l

W

e

Y

/

w

F2

F3

W

w

h

i

/

t

R

e

e

d

Orange

w/Red

Brown
w/Red

and

FRONT PURSUIT

F1

Green
w/Red

Green
w/Red

Brown
w/Red

Orange

w/Yellow

Orange

w/Red

e

t

i

h

W

d

e

R

/

w

W

w

/

h

Y

i

t

e

e

l

l

o

w

White

w/Black

(or Gray)

e

t

i

d

h

e

W

R

/

w

-2-

Mounting Instructions

Please review the separate Mounting Bracket manual that
is also enclosed with your bar for mounting instructions.

Wiring Instructions

All standard lightbar models are designed for 12VDC negative ground vehicles
only. Reverse polarity will cause serious damage to the lightbar and/or vehicle.

Contact the automotive dealer if there are any doubts about the polarity of your vehicle.

Direct Wiring Guide

PLEASE NOTE: If you are using the existing 15-foot cable supplied with the lightbar,

If the wire supplied is too short, Star recommends direct wiring to the terminal block on

the inside of the lightbar, rather than making connections to the end of the wire that is
supplied. This lightbar is designed so that no wire connectors are needed and only a few
common tools are necessary in order to do this. Direct wiring allows the wire connections
to the lightbar to be made in a clean and dry environment, avoiding any problems that may
arise due to weathering on external connections. There is also an increase in voltage loss
with the addition of each connection. Wiring directly inside the lightbar reduces the number
of connections. However, making connections to the wires already provided is an
acceptable alternative, as long as these connections are good electrical connections and
are resistant from weathering effects. For direct wiring into the lightbar, follow the
instructions listed below.

1. Determine the number of wires that you will need to run. The standard harness used in
these lightbars has 16 conductors, plus a drain wire and a foil shield. Your lightbar may
not need all of the wires. Please note which functions your bar has, then review the Wire
Harness Usage Table on page 1 to determine which wires you will need to connect. The
drain wire and foil shield in our standard harness are optional (but recommended) and
are only necessary if you are experiencing RFI problems.

2. Locate the end of the lightbar with the wire harness attached to it. The black terminal
blocks that you will be making your wire connections at, should also be located at the
same end.

3. Remove the dome lens at this end of the lightbar:

Step A: Loosen the 4 screws securing each dome.

Step B: Lift the dome off of the base exposing the

Step C: If your lightbar has a metal plate covering

Step D: Lift the plate off the lightbar exposing the

4. When all work is completed, reinstall the plate and
dome, taking care that the gasket is properly aligned.

you may skip to the Electrical Connections section on page 4.

interior components, or the metal plate
covering the interior components (some
models). If you have no metal plate, skip to
Step 4.

the components, remove all of the screws
holding the plate on. The number of screws
may vary depending upon the layout of your
lightbar.

interior components.

-3-

(Direct Wiring Guide CONT’D)

5. All of the wires coming from outside of the lightbar are terminated on the same side of
the terminal block and the wires leading to the internal components terminate on the
opposite side of the terminal block. Loosen the screws on the terminal block and
remove only those wires that exit the lightbar through the hole in the base. There
may be “dead” wires from the harness connected to the terminal block inside your
lightbar, but there will be no wires connected to the terminal across from them. These
are extra wires in the harness that are not used. Replacing these wires in your new
harness is not necessary.

From Lightbar Components

From Wire Harness

These

Remove

6. Run the new external wires up through the wire bushing into the base and into the
terminal block(s). The function of each of the colored wires in the original wiring harness
is listed in the Wire Harness Usage Table on page 1. There should also be a label next
to the terminal block indicating which color wire should be connected to each terminal.

7. Strip each wire 1/4". Connect the external wires to the proper poles of the terminal
block by inserting the stripped portion of the wire under the rising clamp screw and
tightening down the screw. No wire terminals are needed for connecting wires to this
terminal block.

Be sure to check that no strands of wire are loose and shorting to the
adjacent terminal or to the base of the lightbar.

The correct wire size and color listed in the table on page 1 corresponds directly with the
wiring of the lightbar. All switches used should be rated for at least 125% of their rated load.

8. Once your new wire harness has been connected to the lightbar, you may continue to

the Electrical Connections section.

-4-

Electrical Connections

All standard lightbar models are designed for 12VDC negative ground vehicles
only. Reverse polarity will cause serious damage to the lightbar and/or vehicle.

Contact the automotive dealer if there are any doubts about the polarity of your vehicle.

RF INTERFERENCE

Please take the following steps to help eliminate any Radio Frequency Interference (RFI)
with your two-way radio.

• DO NOT run the power wire for the lightbar along same path as any antenna wires.

• DO NOT run the power wire for the lightbar along same path as any radio power wires.

• DO NOT tap power for the lightbar off of the radio power wires.

• DO NOT mount the lightbar within 20” of any antennae. Sometimes mounting the

lightbar or antenna over by just one foot can make a large difference in the interference.

• Ensure the black wire from the lightbar has a good connection to the negative side of
the battery.

• For all standard Razor lightbars, 15 feet of 16-conductor cable (plus a drain wire and a
foil shield) is supplied with the bar. All wires are color coded and sized at the correct
gauge. If this length is not sufficient, it is recommended that the wire harness be
completely replaced with the only connections to be made directly at the terminal block
inside the lightbar. This will reduce the number of wire connections and help prevent any
weathering problems on these connections. Refer to the Direct Wiring Guide on pages 2-
3 for further instructions on this.

• CAUTION: All wires and switches should be rated for at least 125% of their
maximum current load. In addition, all wires connected to the positive terminal of the

battery should be fused at the battery for 125% of their rated load. The load can be
calculated by adding all lamp wattages and dividing by 13. (Load <Amps> = Total
Watts / 13 volts) Do not use 1/4" diameter glass fuses, as they are not suitable for
continuous duty above 20 amps. A table of recommended wire colors and wire sizes is
provided on page 1. If you are unsure of the current draw, please contact our Customer
Service Department.

• TESTING THE LIGHTBAR BEFORE IT IS PROPERLY FUSED & INSTALLED WILL
VOID THE WARRANTY!!

• The black ground wire should be connected to the negative terminal of your vehicle’s
battery. This wire should be at least #10 AWG wire and be as short as possible in order
to minimize the voltage loss in this wire and reduce any chance of overheating.

• Since many of the lightbars we build have custom components, occasionally wire colors
may slightly vary. If you are unsure of the function of a particular wire, you may test the
function by grounding the black wire and applying +12VDC to the wire in question. Be
sure to use a 20-amp fuse when testing.

-5-

Wire Functions

PLEASE NOTE: There are three different harnesses that could be installed on your lightbar.
Please review the Quick-Install Wiring Guide on page 1 for proper connection of your wires.
Your harness will contain all of the colored wires, the drain wire, and the foil shield, but
most applications will not use every wire. The “dead” wires in the harness will be
connected to the terminal block inside your lightbar, but there will be no wires connected
to the terminal across from them. These “dead” wires can be used for additional
components that may be added at some point in the future, or they may be used to
separately switch components that are currently wired together.

Black: (GROUND) - The black wire is the ground wire and MUST be connected

on EVERY lightbar.

Red: (Power/+12VDC) - The red wire provides the main power to the LED

flashers and/or strobe packs. Connect the red wire directly to continuous
+12VDC through a high-current fuse.

Please Note: When the red wire is connected to +12VDC the pack

will draw a small current (50 mA). If your vehicle will be
sitting for extended periods of time (i.e. more than a
few days), it is recommended the red wire be routed
through a switch or ignition switched relay.

Bare Wire: (Drain/GROUND) - This wire will help eliminate RFI. We recommend that it

be connected to ground.

Purple: (High/Low Power) - The purple wire is optional and can be used to switch

LED applications to low power. Connect the purple wire to ground to
operate the bar under low power.

Red w/Green: (Pattern Select/Touch and Release to +12VDC) - The red w/green stripe

wire is used to select the flash pattern of your LEDs or strobes. It will

normally be left unconnected. (For more detailed instructions, see
Pattern Programming on pages 8-10).

Please note: If you have a lightbar with a strobe pack or LED

flasher, the Red w/Green Stripe wire is only used when
programming the flash pattern. This wire MUST NOT be connected
to continuous +12VDC!!! Once the pattern has been selected, tape
the end of this wire off. (See pages 8-10)

All Other Colors: The remaining wires are typically On/Off controls for the lights shown in the

corresponding Quick-Install Wiring Guide on the page 1. Most applications
will not use every color wire.

Connect the wires that your lightbar utilizes to +12VDC through your switches
(not included). The “dead” wires (not needed) will be connected to the terminal
block inside your lightbar, but there will be no wires connected to the terminal
across from them. These wires do not need to be connected at the other end
of the harness.

-6-

Pattern Programming

● Lightbars with LEDs or strobes can be programmed with the user’s choice of flash

pattern.

● If you have both strobes and LEDs in your lightbar, programming of the strobe

pack(s) and LED flasher(s) must be done separately.

● If you have multiple strobe packs or multiple LED flashers, all of the strobe packs can be

programmed together and all of the LED flashers can be programmed together or each
strobe pack or LED flasher can also be programmed separately, if you desire different
patterns for each.

1. To program the flash pattern turn only the strobe pack(s) or LED flasher on that you

wish to program.

2. Briefly touch the red w/green stripe wire to +12VDC and release it. Continue to briefly

touch and release this wire to +12VDC until you find the pattern desired. The pattern
lists for the strobe packs or various LED flashers can be found below and on the
following three pages.

3. Once you have the pattern you like, turn the pack or flasher off. The pack or flasher will

remember the pattern next time it is activated.

4. Repeat steps 1-3 for each additional strobe pack or LED flasher you wish to program.

5. Once your programming is complete, tape the end of the red w/green stripe wire so that

it does not come into contact with +12VDC.

Strobe Pack Flash Patterns

Pattern Warning Pattern Style

1 Alternating Five-Flash (default)
2 Pseudo-Random
3 Alternating Singleflash
4 Alternating Doubleflash
5 Alternating Quadflash

The strobe packs are defaulted for Five-Flash mode. You can scroll through pseudo­random, singleflash, doubleflash, quadflash, and back to five-flash by touching and
releasing the red w/green stripe wire to +12VDC.

Please note: If you have only the corner strobes activated (white w/yellow wire or white w/

red wire), heads 1 and 4 will alternate (see the center lightbar layout diagram on page

2). If you have only the front or rear strobes activated (brown w/yellow or brown w/
red) then heads 2 and 3 will alternate. If you activate the corners AND the fronts or
rears at the same time, heads 1 and 4 will flash together, opposite of 2 and 3.

Automatic Power Up Head Check

Each 4-outlet power pack comes with a safety feature which checks for proper operation of each
individual strobe head each time you turn on the strobe pack. This feature works by quickly
flashing each head once separately and determining if any of the heads did not flash. If two heads
normally flash together, and one fails and does not flash during the start up test, the strobe pack
will automatically reduce the output power to that particular side so that the “other” remaining
head(s) isn’t over powered. The power to that side will be reduced until the strobe pack is turned
off and on again and the faulty head tests good.

The 4-outlet strobe pack will check all four heads each time the pack is turned on EVEN if the head
select feature is being used and only two heads are to be activated. After checking all four heads,
the pack will begin flashing normally. It takes approximately 0.250 sec. to check all four heads.

Note: If you replace the non-working head, it is necessary to cycle power to the pack

before that head and the one that flashes with it will start flashing again at full
power. (You should never replace a defective head with the pack activated!!)

-7-

LED Flash Patterns

Front and Rear DLX6 and Batwing LED Patterns

(LDF375-1 Flasher)

Pattern Warning Pattern Style

2 Alternating Slow Single (1-5 vs 6-10) (Title 13 Approved)
3 Alternate Pursuit Mode
4 Alternating Quad Flash (1-5 vs 6-10)
5 Alternating Triple (1,2,6,7,8 vs 3,4,5,9,10)
6 Alternating Quint (1,2,6,7,8 vs 3,4,5,9,10)
7 Simultaneous Slow Single (All Modules) (Title 13 Approved)
8 Simultaneous Fast Single (All Modules)
9 Simultaneous Triple Flash (All Modules)
10 Simultaneous Quad Flash (All Modules)
11 Simultaneous Quint Flash (All Modules)
12 Simultaneous Fast Triple Flash (All Modules)
13 Simultaneous Fast Quint Flash (All Modules)
14 In/Out Single (1,2,9,10 vs 3-8)
15 In/Out Triple (1,2,9,10 vs 3-8)
16 In/Out Quint (1,2,9,10 vs 3-8)
17 In/Out Single (1,2,3,8,9,10 vs 4-7)
18 In/Out Triple (1,2,3,8,9,10 vs 4-7)
19 In/Out Quint (1,2,3,8,9,10 vs 4-7)
20 1-5 Steady; 6-10 Single Flash (Title 13 Approved)
21 1-5 Steady; 6-10 Slow Single Flash (Title 13 Approved)
22 6-10 Steady; 1-5 Single Flash (Title 13 Approved)
23 6-10 Steady; 1-5 Slow Single Flash (Title 13 Approved)
24 Sequential Back And Forth
25 Sequential In/Out
26 Burst All w/ Alternating Burst
27 Alternating Burst w/ Simultaneous Double Then Quint
28 Simultaneous Burst w/ Alternating Double Then Quint
29 Hyper-Random
30 Pre-Pop Triple Flash
31 Alternating Pre-Pop Triple Flash
32 Demo (Cycle Through Patterns 1-4,6-9,13-20,25-29)

1 Pursuit Mode

(1 flash/3 sec default)

(3 flashes/9 sec default)

(2 flashes/6 sec default)

Please Note: At any time during the programming sequence, you can reset the flash

pattern back to any of the default patterns (Pattern 1, 18, or 24) by holding
the red w/green Pattern Select wire to +12VDC until the heads flash the
specified number of times, then releasing it.

Each LED flasher has 20 output terminals (10 pairs). The two terminals in each pair are
electrically connected and will flash at the same time. The numbers in parenthesis in the
list above indicate which output pairs flash together vs. the pairs they flash opposite of.

Front and Rear DLX6 and Batwing LED Flasher Units

(LDF375-1 / 8070-375-1)

White

Orange

Brown

Yellow

Red/Green

Black

Purple

White = Corner Enable
Orange = Outboard Enable
Brown = Inboard & Ends

Yellow = Cruise

Please Note: The 20 output
terminals are enabled by 3
different inputs:

White - 1,2,9,10 (Corners)
Orange - 3,8 (Outboard)
Brown - 4,5,6,7 (Inboard & Ends)

d

e

R

e

g

r

a

L

Output Pair

Red/Green = Pattern Select
Black = Ground
Purple = High/Low Power
Large Red = Power

-8-

1
2
3
4
5
6
7
8
9

10

(LED Pattern Programming CONT’D)

Takedown or Alley Light DLX6 and Batwing LED Patterns

(LDF375-2 Flasher)

Pattern Warning Pattern Style

2 Alternating Slow Single (1,3 vs 2,4) (Title 13 Approved)
3 Alternate Pursuit Mode
4 Alternating Quad Flash (1,3 vs 2,4)
5 Alternating Triple (1,3 vs 2,4)
6 Alternating Quint (1,3 vs 2,4)
7 Simultaneous Slow Single (All Modules) (Title 13 Approved)
8 Simultaneous Fast Single (All Modules)
9 Simultaneous Triple Flash (All Modules)
10 Simultaneous Quad Flash (All Modules)
11 Simultaneous Quint Flash (All Modules)
12 Simultaneous Fast Triple Flash (All Modules)
13 Simultaneous Fast Quint Flash (All Modules)
14 In/Out Single (1,3 vs 2,4)
15 In/Out Triple (1,3 vs 2,4)
16 In/Out Quint (1,3 vs 2,4)
17 Simultaneous Double Flash, Post-Pop
18 Simultaneous Triple Flash, Post-Pop
19 Simultaneous Quint Flash, Post-Pop
20 Alternating Double Flash, Post-Pop (1,3 vs 2,4)
21 Alternating Triple Flash, Post-Pop (1,3 vs 2,4)
22 Alternating Quint Flash, Post-Pop (1,3 vs 2,4)
23 Alternating Pre-Pop Quint Flash (1,3 vs 2,4)
24 Sequential Back And Forth
25 Sequential In/Out
26 Burst All w/ Alternating Burst
27 Alternating Burst w/ Simultaneous Double Then Quint
28 Simultaneous Burst w/ Alternating Double Then Quint
29 Hyper-Random
30 Demo (Cycle Through Patterns 1-4,6-9,13-20,25-29)

1 Pursuit Mode

The numbers in parenthesis in the list above indicate which output pairs flash
together vs. the pairs they flash opposite from.

(1 flash/3 sec default)

(3 flashes/9 sec default)

(2 flashes/6 sec default)

Please Note: Please Note: At any time during the programming sequence, you can reset

the flash pattern back to any of the default patterns (Pattern 1, 18, or 24) by
holding the red w/green Pattern Select wire to +12VDC until the heads flash
the specified number of times, then release it.

Takedown (Pursuit) and Alley LED Flasher Units

White

Orange

Brown

Yellow

Black

Red/Green

Purple

White = Steady 1 & 2 (Takedowns)
Orange = Steady 4 & 5 (Driver Alley)
Brown = Steady 3 (Passenger Alley)
Yellow = Flash 1 & 2 (Pursuits)

(LDF375-2 / 8070-375-2)

Function Connect to Pairs

Takedown/Pursuit Lights 1 & 2
Passenger Alley 3
Driver Alley 4 or 5

Output Pair

1
2
3
4

Black = Ground

n
e
e

d

Red/Green = Pattern Select

r

e

G

R

/

Purple = High/Low Power

e

e

u

g

l

r

B

a

L

Large Red = Power

5

-9-

(LED Pattern Programming CONT’D)

Patterns for All LEDs Excluding DLX6 and Batwing

(LDF398 Flasher)

Pattern Warning Pattern Style

1 Pursuit Mode
2 Alternating Slow Single (1-5 vs 6-10) (Title 13 Approved)
3 Alternate Pursuit Mode
4 Alternating Quad Flash (1-5 vs 6-10)
5 Alternating Triple (1,2,6,7,8 vs 3,4,5,9,10)
6 Alternating Quint (1,2,6,7,8 vs 3,4,5,9,10)
7 Simultaneous Slow Single (All Modules) (Title 13 Approved)
8 Simultaneous Fast Single (All Modules)
9 Simultaneous Triple Flash (All Modules)
10 Simultaneous Quad Flash (All Modules)
11 Simultaneous Quint Flash (All Modules)
12 Simultaneous Fast Triple Flash (All Modules)
13 Simultaneous Fast Quint Flash (All Modules)
14 In/Out Single (1,2,9,10 vs 3-8)
15 In/Out Triple (1,2,9,10 vs 3-8)
16 In/Out Quint (1,2,9,10 vs 3-8)
17 In/Out Single (1,2,3,8,9,10 vs 4-7)
18 In/Out Triple (1,2,3,8,9,10 vs 4-7)
19 In/Out Quint (1,2,3,8,9,10 vs 4-7)
20 1-5 Steady; 6-10 Single Flash (Title 13 Approved)
21 1-5 Steady; 6-10 Slow Single Flash (Title 13 Approved)
22 6-10 Steady; 1-5 Single Flash (Title 13 Approved)
23 6-10 Steady; 1-5 Slow Single Flash (Title 13 Approved)
24 Sequential Back And Forth
25 Sequential In/Out
26 Burst All w/ Alternating Burst
27 Alternating Burst w/ Simultaneous Double Then Quint
28 Simultaneous Burst w/ Alternating Double Then Quint
29 Hyper-Random
30 Demo (Cycle Through Patterns 1-4,6-9,13-20,25-29)

(Default)

Each LED flasher has 20 output terminals (10 pairs). The two terminals in each pair are
electrically connected and will flash at the same time. The numbers in the list above, in
the parenthesis, indicate which output pairs flash together vs. the pairs they flash
opposite of.

Please Note: At any time during the programming sequence, you can reset the flash

pattern back to the default mode (Pattern 1 – Pursuit) by holding the red
w/green Pattern Select wire to +12VDC for 5 seconds, then releasing it.

Flasher Unit for All LEDs Excluding DLX6 and Batwing

(LDF398 / 8070-285-1)

White

Orange

Brown

Purple

Black

Red/Green

White = Corner Enable
Orange = Outboard Enable
Brown = Inboard & Ends
Purple = High/Low Power

Please Note: The 20
output terminals are
enabled by 3 different
inputs:

White - 1,2,9,10 (Corners)
Orange - 3,8 (Outboard)
Brown - 4,5,6,7 (Inboard
& Ends)

d

e

Black = Ground

R

e

Red/Green = Pattern Select

g

r

Large Red = Power

a

L

-10-

Output Pair

1
2
3

4
5
6
7
8
9

10

Parts

Please note that these items are not drawn to scale. Many have been enlarged to show
more detail.

-11-

(Parts CONT’D)

*=COLOR

Please note that these items are not drawn to scale.

-12-

Switches and Switchboxes

SP3860-1 SP3860-2 SP3860-3 SP3860-4

ROTATORS

STROBES

SB4020

LEFT

ALLEY

SP1515

SP3015

WORK

RIGHT

LIGHTS

ALLEY

FLASHERS

MODE

1 2 3

SB1515

SB3015

GRILL

HEADLIGHT

LIGHTS

FLASHER

SB4040

CORNER

LIGHTS

TAKE

DOWN

-13-

Troubleshooting

If a light on your bar fails to work, please refer to this section to help solve your problem.
If you still cannot resolve your problem, please contact our Customer Service
Department at 585-226-9787.

The chart below contains some basic guidelines for troubleshooting any problems you may
experience with your bar. The section following the chart will explain in further detail how to
perform some of the troubleshooting tasks.

Symptom:

One single LED light is Out LED Head needs to be replaced

One LED head does not fl ash Check wiring between LED head and fl asher unit

Multiple LED heads not
flashing

One flashing light out

Multiple flashing lights out Check power to terminal block

One remote strobe head out Check the strobe head

Multiple strobe heads out

Possible Solutions

Check LED head
Check that + 12VDC is applied to control line for that head

Check power to terminal block
Check that the bar is properly grounded
Check power from terminal block to LE D flasher unit
Check that the LED flasher unit is grounded properly
Check that + 12VDC is applied to control line for those heads
Check that the red w/green stripe pattern select wire is not connected to
+12VDC

Check bulb
Check power wire from flasher unit to bulb
Check that the bulb is grounded

Check that the bar is properly grounded
Check power from terminal block to flasher unit
Check that the flasher unit is grounded properly

Check the cable from the remote pack to the strobe head
Check power to terminal block

Check power to strobe pack Power Outlet (PWR)
Check power to strobe pack Control Outlets (CTRL)
Check that the pack is properly grounded
Check that the red w/green stripe pattern select wire is not connected to
+12VDC

-14-

Determining if the bar is properly grounded:

1. While the bar is turned on, using a test meter, measure the voltage from the base of the bar
itself to the negative post of the battery or a good chassis ground if the battery can’t be easily
reached. You may need to scrape away a bit of anodizing or paint in order to ensure a good
connection with the probe of your test meter.

2. If the difference shown is greater than .25 volts, then your ground is not sufficient.

3. If the ground is insufficient, locate the ground wire connection in your lightbar by removing the
dome over the section where the wires enter the bar. Please follow the appropriate dome
removal instructions listed earlier in this manual when removing this dome. The ground wire is
the large (10AWG) black wire attached to the inside of the lightbar base with a ring terminal.
Check the integrity of the connection of the ground wire to both the lightbar base and at the
other end to a good chassis ground.

4. While inspecting the ground wire connections you should also check that the wire itself is not
damaged. Carefully inspect the wire along its entire length, paying special attention to those
areas where the wire passes through any holes that may have sharp edges, which can
damage the wire, and the areas where the wire makes any sharp bends.

Checking the power to the terminal block
(Determining if the proper voltage is reaching your bar):

1. Locate the terminal block in your lightbar by removing the dome over the section where the
wires enter the bar. Please follow the appropriate dome removal instructions listed earlier in
this manual when removing this dome. After entering the bar, the wires will be connected to
the terminal block with a number of small Phillips head screws.

2. With the bar turned on, use a test meter to test the voltage at the terminal block. A nominal

12.5 volts should be present. Low voltage can cause erratic flashing in strobe heads or even
complete failure of the heads. A minimum of 10.5 volts should be present for the pack to
operate properly. Low voltage in strobe lights, flashing lights, or LEDs can result in lowered
intensity or even complete failure.

3. Be sure to test each wire that comes into the terminal block for proper voltage.

4. Carefully inspect each wire in the terminal block. Check that the ends of the wires have not
frayed and shorted against one another or against the base. This may cause lights to operate
inadvertently or may result in the failure of lights.

Checking one non-working strobe or LED head:

If a problem exists in only one head, a strobe tube or LED head may have burned out, or
there may be an open electrical connection in the wiring harness or strobe head.

1. Check connections at and between the strobe pack and the faulty strobe head or between the
flasher unit and LED head, including all wiring.

2. Disconnect both the faulty head and a working head.

3. Check the faulty head by connecting it into the side you just unplugged the working head from.
If the faulty head still does not work, then the head is bad and will need to be replaced.

4. If the head that was not flashing works when connected to the other side, the problem
probably lies in the power pack or flasher unit. Verify this by plugging the other head
(the original working head you just unplugged) into the side that previously had the non­working head.

-15-

Checking multiple non-working strobe or LED heads:

If two or more of the heads connected to one of the packs are not flashing, follow these
steps to determine the problem:

1. Check the power to the terminal block as explained on the previous page.

2. Check that the bar is grounded properly as explained on the previous page.

3. Check all fuses, including those at the battery, at the switch panel, in the dash, and on
the pack (if applicable). Remove these fuses, and check them to confirm they have not
blown. Replace any blown fuses with only fuses of identical values. Replacing the fuse
with the wrong rating may damage your pack and/or vehicle, and will void your warranty.

4. Check that the proper voltage is reaching the pack or flasher unit with the vehicle turned
off and while the bar is running. For strobe packs, measure the voltage across the red
wire (pin 1) and the black or blue wire (pin 2) of the PWR connector on the power pack.
Push the probes of the test meter down into the connector at the wire entry points to
contact the terminals for the measurement. Note this reading. A nominal 12.5 volts
should be present. Low voltage to the pack can cause erratic flashing in the heads or
even complete failure of the heads. A minimum of 10.5 volts should be present for the
pack to operate properly. If you do not have proper voltage present skip to step 8. If
your pack is receiving sufficient voltage then continue to step 5.

5. Check that the proper voltage is reaching the Black wire and White wire of the CTRL
plug on your strobe pack with the vehicle turned off and while the bar is running.
Measure the voltage across the Black wire (pin 2) and a good chassis ground. Push the
probes of the test meter down into the connector at the wire entry points to contact the
terminals for the measurement. Note this reading. Also check the voltage on the White
wire. A nominal 12.5 volts should be present. A minimum of 10.5 volts should be
present for the pack to operate properly. If you do not have proper voltage present, skip
to step 8. If your pack is receiving sufficient voltage then continue to step 6.

6. Check that there is NO VOLTAGE on the Red w/Green Stripe wire (Pattern Select wire)
of the CTRL plug on your strobe pack. Measure the voltage across the Red w/Green
stripe wire (pin 1) and a good chassis ground. Push the probes of the test meter down
into the connector at the wire entry points to contact the terminals for the measurement.
If there is voltage being applied to this wire, it will prevent the strobe pack from flashing.

7. If the leads in one of the heads have shorted out, the output voltage of the other heads
may be held down as well. To test for this, unplug all of the heads and plug them in
individually, one at a time. If your problem is a result of a shorted head, then the other
heads should function properly if the faulty head is no longer connected. Note: A
burned out strobe tube does not cause a short and will not affect the operation of the
remaining heads. If the problem is not with a shorted head and if proper voltage is
reaching the pack, the problem is most likely internal to the pack. Call Star to obtain an
R.G.A. number to return the pack for service.

8. If sufficient voltage is not reaching the pack perform the following tests: With the vehicle
turned off and while the pack is running, measure the battery voltage at the battery. A
nominal 12.5 volts should exist. Note this voltage. If this voltage is below 10.0 volts the
pack will not function properly and the problem is with the battery. This reading should
not be more than 1-1.25 volts higher than the reading in the 4th step. If there is an
excessive difference then continue on to the next step.

9. With the vehicle not running and the lightbar on, measure the voltage in the red wire by
taking a reading from the positive side of the battery to pin 1 of your switch. If this
reading exceeds 0.25 volts then there is a poor connection between the switch and the
battery in the red wire and it should be checked.

10. If you still have not located the problem, troubleshoot the connections between the good
chassis ground and pin 2 (black wire) of the PWR connector on the power pack, while
the lightbar is running. If this reading exceeds 0.25 volts then there is a poor connection
between the switch and the ground in the black wire and it should be checked.

11. This same procedure can be used to check the wires between the terminal block and the pack.
Place one probe on the terminal at the terminal block and the other probe into the terminal with
the corresponding wire color in the connector on the pack. Once again if any of the readings
exceed 0.25 volts then you should check those wires and their connections.

-16-

ONE YEAR LIMITED WARRANTY

LED FIVE YEAR LIMITED WARRANTY

The manufacturer warrants each new product, under normal use, against factory defects in
material and workmanship for one year after the date of purchase. The manufacturer
warrants the LED components in this light against factory defects in material and workmanship
for five years after the date of purchase. The owner will be responsible for returning to the
Service Center any defective item(s) with the transportation costs prepaid. The manufacturer
will, without charge, repair or replace at its option, products, or part(s), which its inspection
determines to be defective. Repaired or replacement item(s) will be returned to the
purchaser with transportation costs prepaid from the service point. A copy of the purchaser's
receipt must be returned with the defective item(s) in order to qualify for the warranty
coverage. If a copy of the receipt is not provided, the warranty period shall cover five years
from the date of manufacture.

Exclusions from this warranty include, but are not limited to, bulbs, strobe tubes, domes, and/
or the finish. This warranty shall not apply to any light, which has been altered, such that in the
manufacturer's judgment, the performance or reliability has been affected, or if any damage
has resulted from abnormal use or service. This warranty does not apply to defect or damage
occurring as a result of disaster, accident, abuse, misuse, lightning, power surges, or failure to
follow instructions in any enclosed manuals. Any damage or defects occurring as a result of
any unauthorized service or repairs by unauthorized persons shall be excluded from this
warranty.

There are no warranties expressed or implied (including any warranty of merchantability or
fitness), which extend these warranty period. The loss of use of the product, loss of time,

inconvenience, commercial loss or consequential damages, including costs of any labor, are
not covered. The manufacturer reserves the right to change the design of the product

without assuming any obligation to modify any product previously manufactured.

This warranty gives you specific legal rights. You might also have additional rights that may
vary from state to state. Some states do not allow limitations on how long an implied warranty
lasts. Some states do not allow the exclusion or limitation of incidental or consequential
damages. Therefore, the above limitation(s) or exclusion(s) may not apply to you.

If you have any questions concerning this or any other Star product,

please contact our Customer Service Department at [phone].

If a product must be returned for any reason, please contact

our Customer Service Department to obtain a

Returned Materials Authorization number (RMA #) before you ship the product to Star.

Please write the RMA # clearly on the package near the mailing label.

-17-