Star Headlight & Lantern 6600 User Manual

INSTALLATION AND INSTRUCTION MANUAL
TM
Aerostar
Aerostar
Aerostar Aerostar
PLITSTR335 REV. G 8/16/12
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
Table of Contents
MOUNTING INSTRUCTIONS 2
(For Mounting see Mounting Bracket Manual)
WIRING INSTRUCTIONS 2-9
Wire Harness Replacement 2-3 Electrical Connections 4 Remote Power Supply Connections for Linear Strobe Heads 5-8
STROBE PATTERN PROGRAMMING 8
LED PATTERN PROGRAMMING 9-10
TROUBLESHOOTING 11-14
PARTS 15-17
SWITCHES 18
WARRANTY 18
SERVICE 18
NOTICE
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.
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.
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.
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QUICK-INSTALL WIRING GUIDE
All lightbars are shipped with a Wire Harness Assembly Checklist that is unique to your bar and will define what each wire controls. You can also use the chart below for general reference.
Please note: Depending upon the components in your lightbar, the wire colors used in your harness may differ slightly from the chart below.
Wire Harness Usage Chart
LIGHT(S) WIRE COLOR AWG
Connect to Negative Side of Battery
-12 VDC /Ground/Neutral Black 10
Connect to +12VDC
Rotating Halogen Lights Orange 14 Secondary Rotator Orange w/Black Stripe 14 360° Strobe, 360° Halo, or Strobe Power Pack* Red 14 Front Strobe Heads On/Off Rear Strobe Heads On/Off Pattern Select (Strobe and/or LED)‡ Red w/Green Stripe 22 Alternate Strobe Pack PWR Red w/Black Stripe 14 LED Flasher Power LED High/Low Control Purple 18 Front Take-Down/Work Lights Green w/Yellow Stripe 14 Rear Floods/Work Lights White w/Orange Stripe 14 Front Alternating Flashers White w/Brown Stripe 16 Rear Alternating Flashers White 16 Driver’s Side Alley Light Blue 16 Passenger Side Alley Light Gray 16 Left Turn Signal Yellow 16 Right Turn Signal Green 16 Tail Lights & ID Marker Lights Brown 18 Intersection Clearing Lights White w/Blue Stripe 18 Alternate Power Red w/White Stripe 14 Traffic Director
Please note: If you have a lightbar with a strobe pack or LED flasher, the
(4-Head Packs Only)
(4-Head Packs Only)
(LDF369 or LDF398)
* White w/Green Stripe 22
* Black w/Green Stripe 22
Orange w/Red Stripe 16
* See Remote Strobe Power Supply Connection section on pages 5-8
See Pattern Programming section on page 9-11
Separate Bundled 9-Conductor Cable
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 page 10)
)
)
)
)
Minimum
Please find to the right a sample of the terminal block, showing the correct wire colors from a lightbar using the 271STROBE cable.
)
CTRL Power Plug
PWR Plug Strobe Pack 1
PWR Plug Strobe Pack 2
CTRL Plug
(
White w/Brown
White w/Blue
Blue
Blue
Green w/Yellow
White w/Blue
White w/Brown
Green w/Yellow
Red w/White
Red
Red (
Red (
Red
Red w/Black
Red w/White
Red w/Green
CTRL Power Plug
To Lightbar Components
White (
Black (
From Wire Harness
Black w/Green
White w/Green
)
LED Flasher
White
Orange
Orange
Gray
Black
Red (
White
Orange w/Red
Bare
Bare
Gray
Black
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Mounting Instructions
Please review the separate Mounting Bracket manual that is also enclosed with your bar for mounting instructions.
Wiring Instructions
PLEASE NOTE: If you are using the existing 15-foot cable supplied with the lightbar,
you may skip to the Electrical Connections section on page 4.
Wire Harness Replacement
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. Use the Wire Usage Table shown on page 1 to determine how many wires you will need to run.
2. After identifying the necessary wires, select appropriate wire sizes and colors.
3. Locate the end of the lightbar that has the external wires entering the base of the lightbar. The black terminal block(s), which you will be making your wire terminations to, should also be located at this same end.
4. Remove the outer dome to expose the terminal block.
Step 1 : Remove the
two screws holding the
endcap to the
lightbar base.
Step 2 : Loosen the two screws that
are holding the dome to the center divider section.
Step 3 : Slide the dome (with the attached
endcap) off the end of the base, exposing the interior components.
Step 4 : When all work is completed, reverse the steps to reinstall
the dome, taking care that the gasket is properly aligned.
Step 2
Step 3
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(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.
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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.
Use the Wire Harness Usage Table on page 1 to identify the wire colors and connect the appropriate wires to your switches supplying +12VDC.
For all standard lightbars, 15 feet of cable 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 Wire Harness Replacement section 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.
The Wire Harness Usage Table on page 1 lists the different wire colors and lights controlled by those wires. Your harness may contain unused wires. 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.
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.
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