Star Headlight & Lantern RSK996P User Manual

Download

# of Total

Joules

REMOTE STROBE PACKS

Models RP966, and RP996

Owner's Manual & Installation Instructions

Model Heads Watts per Side Amps

RP966 6 60 20.7J 7.8A RP996 6 90 31.1J 9.4A

PLITSTR355 REV. A 8/16/06

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NOTICE

SAFETY WARNINGS 1 MOUNTING 2 WIRING INSTRUCTIONS 3-9 PATTERN SELECTION 8 STATUS LED 10 CONNECTING THE REMOTE HEADS 11 TROUBLESHOOTING 12-13 SERVICE & WARRANTY 14

Table of Contents

IMPORTANT: Please read all of the following instructions before installing your new

strobe system. This instruction sheet applies only to the models listed.

4 CAUTION: All of our remote power supplies are polarity sensitive. They are polarity

protected only if the appropriate fuse is used. All wires connected to the positive terminal of the battery should be fused at the battery for their rated load. Testing the system before this fuse is properly installed will void the warranty on the light.

4 Opening or tampering with your remote power supply will void the warranty.

The remote power supply must be mounted against a smooth metal surface in a dry location. Water damage to the power supply will also void the warranty. Typical mounting locations of your power supply include the interior firewall, beneath the seat of a truck, or inside a large toolbox.

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.

-1-

Mount the pack on a smooth metal surface to allow for adequate heat dissipation. Do not

Mounting

mount the pack near any external heat source, as this will retard its ability to dissipate heat sufficiently. Mount the pack using four bolts (not included). When mounting, make sure a good electrical connection exists between the mounting plate and the vehicle chassis. This will help to eliminate any RF interference.

" DIA.

When mounting the power pack and accessories, please be sure to keep any radio frequency sensitive equipment at least 20” from the power pack, cables, and/or wires which make up your strobe system. The pack has been designed to limit RFI emissions, but certain very sensitive equipment may still be affected. Symptoms may include, but are not limited to, sporadic ope ration 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 this strobe system. Any antennae mounted in the proximity of the

system may cause your radio to suffer the aforementioned results.

PATTERN

SELECT

FUSE

POWER

-2-

+ + +

ENABLE

STATUS

STAR-PAK

STROBE POWER SUPPLY

RP966/RP996

POS 1

POS 2

1-2 3-4 5-6

" 4

STROBE HEADS

A B C

POS 1 1+2 3+4 5+6

POS 2 1_4 5+6

LOW

Wiring

STAR-PAK

STROBE POWER SUPPLY

RP966/RP996

POS 1

POS 2

3-41-2 5-6

STROBE HEADS

POS 1 1+2 3+4 5+6

POS 2

1 _4 5+6

LOW

HIGH/LOW - HEAD

SELECT JUMPER

PATTERN

SELECT

FUSE

POWER

ENABLE

STROBE

OUTLETS

STATUS

POWER

PLUG

ENABLE

PLUG

POWER Plug

The power plug is included with your power pack and comes complete with an 8-12” wiring harness. This will be connected to the outlet on your pack labeled POWER.

POWER PLUG FOR

RP966 AND RP996

Red = Power

Black = Ground

White = Pattern Select

PLUG

POWER

ENABLE Plug

These strobe packs also utilize another plug, identical to the Power Plug, which plugs into the jack labeled ENABLE. The connection

ENABLE PLUG FOR

RP966 AND RP996

of the ENABLE wires will allow you to set the pack up in a number of different configurations. Here are the different configurations you may choose from when installing the RP966 and RP996 packs:

• All 6 Heads On and Off Together (High Power Only)

Wire Jumper Set For Jumper Set For Color 3-Pair Head Select High/Low Option

Red = Enable Heads 5 & 6 Enable Heads 5 & 6 Black = Enable Heads 3 & 4 Enable Heads 1, 2, 3, & 4 White = Enable Heads 1 & 2 High/Low Option Switching

• All 6 Heads On and Off Together (Low Power Only)

• All 6 Heads On and Off Together (High/Low switching Option)

• 2-Heads/4-Heads Separate Activation (High Power Only)

• 2-Heads/4-Heads Separate Activation (Low Power Only)

• 2-Heads/4-Heads Separate Activation (High/Low Switching Option)

• 3-Pair Separate Activation (High Power Only)

Decide which configuration will work best for you, set your jumper accordingly (see next page), and proceed to the appropriate section to connect the wires from the POWER and

ENABLE connectors.

-3-

PLUG

ENABLE

Setting the High/Low – Head Select Jumper

If you wish to activate three separate pairs of heads i

ndependently of each other,

If you would like to utilize both high and low power, or you will be activating

all 6 of

The RP966 and RP996 remote strobe packs allow you to choose whether you would prefer to have the ability to switch three pairs of heads On/Off separately OR if you would like the ability to switch between High and Low power, switching two heads separate from the other four heads. Prior to installation, you should decide which setting will work best for you, and set the jumper appropriately.

leave the Head Select - High/Low Jumper in the 3 -Pair Head Select position (default) shown below. The jumper should be on the left two pins, closest to the edge of the pack. The ENABLE wires will function as follows:

White = Enable Heads 1 & 2 Black = Enable Heads 3 & 4

Red = Enable Heads 5 & 6

your strobe heads together with one On/Off switch, or if you will be activating two heads independently of the other four heads and do not need to operate three different pairs of heads, the jumper should be moved to the right two pins, towards the center of the pack. This will allow you to switch one pair of heads on one switch, the other four heads on another switch, and select high or low power on a third switch. The ENABLE wires will function as follows:

Black = Enable Heads 1, 2, 3, & 4 Red = Enable Heads 5, & 6 White = High/Low Option Switching

LEFT POSITION

RIGHT POSITION

-4-

GROUND

All Heads On and Off Together (High Power Only)

(This setup is typically used for most “On/Off” applications)

For this set up, only one On/Off switch (not included) is necessary.

1. Connect the black wire from the POWER connector to a good chassis ground.

2. Connect all three wires (red, black, and white) from the ENABLE plug and the red wire from the POWER connector to a +12VDC power source through your On/Off switch.

3. The white wire from the POWER connector will be left unconnected for now. Once your system is installed, the white wire will be used to program the flash pattern. Proceed to the Pattern Selection section on page 8.

RP966/RP996

All Heads Activate Together

High Power Only

(Set Jumper in

High/Low Option Position)

WHITE

ENABLE

CONNECTOR

POWER

CONNECTOR

All Heads On and Off Together (Low Power Only)

For this set up, only one On/Off switch (not included) is necessary.

1. Connect the black wire from the POWER connector and the white wire from your ENABLE plug to a good chassis ground.

2. Connect the red and black wires from the ENABLE plug and the red wire from the POWER connector to a +12VDC power source through your On/Off switch.

3. The white wire from the POWER connector will be left unconnected for now. Once your

PLUGS

BLACK

INTO

POWER

PAK

RED

PLUGS

BLACK

INTO

POWER

PAK

WHITE

Pattern Select: Touch and release to +12VDC to set pattern then tape off

SP3860-1-15 LIGHTED SWITCH PANEL

GOOD

CHASSIS

GROUND

RED

3 232 1

OFF

SW1

(REAR VIEW)

FUSE

15 AMP

CONNECT TO +12 VDC

BLACK

GOOD

CHASSIS

system is installed, the white wire will be used to program the flash pattern. Proceed to the Pattern Selection sect ion on page 8.

All Heads Activate Together

ENABLE

CONNECTOR

POWER

CONNECTOR

RP966/RP996

Low Power Only

(Set Jumper in

High/Low Option Position)

WHITE

PLUGS

BLACK

INTO

POWER

PAK

RED

PLUGS

BLACK

INTO

POWER

PAK

WHITE

Pattern Select: Touch and release to +12VDC to set pattern then tape off

GOOD CHASSIS GROUND

SP3860-1-15 LIGHTED SWITCH PANEL

3 2

2 1

(REAR VIEW)

OFF

SW1

GOOD

CHASSIS

GROUND

RED

FUSE

15 AMP

BLACK

CONNECT TO +12 VDC

GOOD CHASSIS GROUND

-5-

All Heads On and Off Together

(With High/Low Power Switching Option)

1. Use Star Model #SP3860-2H-OP switch panel (not included), or any other standard two- switch switch panel capable of delivering 15 amps.

2. Connect the black wire from the POWER connector to a good chassis ground.

3. Connect the black and red ENABLE plug wires and the red POWER plug wire to +12VDC through the first On/Off switch .

4. The white wire from the ENABLE plug allows utilization of the High//Low (Day/Night Mode) option. The white wire from your ENABLE plug should be connected to the second switch. When the white wire is connected to power through your second switch, the pack will run in high power mode. When the second switch is in the “off” position, yo ur pack will operate in “Night Mode” (low power).

5. The white wire from the POWER connector will be left unconnected for now. Once your

system is installed, the white wire will be used to program the flash pattern. Proceed to the Pattern Selection sect ion on page 8.

All Heads Activate Together

(Set Jumper in High/Low Option Position)

RP966/RP996

With High/Low Option

ENABLE

CONNECTOR

POWER

CONNECTOR

WHITE

PLUGS

BLACK

INTO

POWER

PAK

RED

PLUGS

INTO

BLACK

POWER

PAK

WHITE

Pattern Select: Touch and release to +12VDC to set pattern then tape off

SP3860-2H-OP LIGHTED SWITCH PANEL

ONHIGH

BLUE

GOOD

CHASSIS

GROUND

3 2

SW2

RED

3 2 11

OFFLOW

SW1

15 AMP

(REAR VIEW)

FUSE

CONNECT TO +12 VDC

BLACK

GOOD CHASSIS GROUND

2-Head/4-Head Separate Activation (High Power Only)

(diagram on next page)

1. For this set up only two On/Off switches are necessary (not included). Use Star Model #SP3860-2 switch panel, or any other standard two-switch switch panel capable of delivering 15 amps.

2. Connect the black wire from the POWER connector to a good chassis ground.

3. Connect the red wire from the ENABLE plug to +12VDC through your first switch.

4. Connect the black wire from the ENABLE plug to +12VDC through your second switch.

5. Connect the red wire from the POWER plug and the white wire from the ENABLE plug to +12VDC through a 15 amp fuse (not included).

Please Note: When the red POWER 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 that all +12VDC wires be routed through an ignition switched power source.

6. The white wire from the POWER connector will be left unconnected for now. Once your

system is installed, the white wire will be used to program the flash pattern. Proceed to the Pattern Selection section on page 8.

-6-

2-Head/4-Head Separate Activation (High Power Only) (CONT’D)

is recommended that all

+12VDC wires

be routed through an ignition switched power source.

Two-Head/Four-Head Switching

(Set Jumper in High/Low Option Position)

ENABLE

CONNECTOR

POWER

CONNECTOR

Please Note: When the red POWER 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 that all +12VDC wires be routed through an ignition switched power source.

RP966/RP996

High Power Only

RED

PLUGS

BLACK

INTO

POWER

PAK

WHITE

RED

PLUGS

BLACK

INTO

POWER

PAK

WHITE

Pattern Select:

Touch and release to +12VDC to set pattern then tape off

SP3860-2 LIGHTED SWITCH PANEL (REAR VIEW)

2 11

OFF

SW1

SW2

RED

BLUE

FUSE

15 AMP

CONNECT TO +12 VDC

FUSE

15 AMP

BLACK

CONNECT TO +12 VDC

GOOD CHASSIS GROUND

2-Head/4-Head Separate Activation (Low Power Only)

1. For this set up, only two On/Off switches are necessary (not included). Use Star Model #SP3860-2 switch panel, or any other standard two-switch switch panel capable of delivering 15 amps.

2. Connect the black wire from the POWER connector and the white wire from the ENABLE plug to a good chassis ground.

3. Connect the black wire from the ENABLE plug to +12VDC through your second switch.

4. Connect the red wire from the ENABLE plug to +12VDC through your first switch.

Please Note: When the red POWER 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 all +12VDC wi res be routed through an ignition switched power source.

5. The white wire from the POWER connector will be left unconnected for now. Once your system is installed, the white wire will be used to program the flash pattern. Proceed to the Pattern Selection section on page 8.

RP966/RP996

Two-Head/Four-Head Switching

Low Power Only

(Set Jumper in High/Low Option Position)

WHITE

ENABLE

CONNECTOR

POWER

CONNECTOR

PLUGS

INTO

POWER

PLUGS

INTO

POWER

PAK

Please Note: When the red POWER 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

WHITE

BLACK RED

RED BLACK

WHITE

Pattern Select: Touch and release to +12VDC to set pattern then tape off

SP3860-2 LIGHTED SWITCH PANEL (REAR VIEW)

2 11

OFF

SW2

BLUE

GOOD CHASSIS GROUND

OFF

SW1

RED

FUSE

15 AMP

CONNECT TO +12 VDC

GOOD CHASSIS GROUND

FUSE

15 AMP

CONNECT TO +12 VDC

GOOD CHASSIS GROUND

BLACK

-7-

2-Head/4-Head Separate Activation (With High/Low Power Switching Option)

1. Simultaneous Singleflash

or 3-Pair Independent Activation (High Power Only)

(diagram on next page)

1. Use Star Model #SP3860-3 switch panel (not included), or any other standard three -switch switch panel capable of delivering 15 amps.

2. Connect the black wire from the POWER connector to a good chassis ground.

3. Connect the red wire from the ENABLE plug to +12VDC through your first switch.

4. Connect the black wire from the ENABLE plug to +12VDC through your second switch.

5. Connect the white wire from the ENABLE plug to +12VDC through your third switch.

If the Head Select/High-Low Jumper is in the High/Low position: (see page 4)

The white wire from the ENABLE plug allows utilization of the High/Low (Day/Night Mode) option. The white wire from your ENABLE plug should be connected to the third switch. When the white wire is connected to power through your third switch, the pack will run under high power (Day Mode). When the third switch is in the “off” position, your pack will operate under low power (Night Mode).

If the Head Select/High-Low Jumper is in the 3-Pair Head Select position: (see page 4)

The pack will run under high power and each switch will control one pair of heads.

6. The white wire from the POWER connector will be left unconnected for now. Once your system is installed, the white wire will be used to program the flash pattern. Proceed to the Pattern Selection section on below.

1. The white wire on the POWER cable for the RP966 and RP996 packs allows you to select what pattern you would like the strobe heads to exhibit.

2. Once your switch, strobe pack, cables, and heads are installed, activate your strobe system by turning all the switches on.

3. Using the white wire on the POWER cable, select your flash pattern by slowly touching it to +12VDC for about two seconds and releasing it. Continued touching for two seconds and releasing of the white wire to +12VDC will scroll through the following 24 different patterns:

2. Alternating Single flash

3. Alternating Doubleflash

4. Alternating Tripleflash

5. Alternating Quadflash

6. Alternating Quintflash

7. Double-Duty

8. Doubleflash Alternating, Doubleflash Simultaneous

9. Alternating Climber

10. Leadfoot

11. Singleflash Knight Rider Effect†

12. Quadflash Knight Rider Effect†

13. Doubleflash Left†

Pattern Selection

4. Once you have found the desired pattern, you can turn off the system. The strobe pack will “remember” the last selected pattern when switched off and that pattern will be displayed the next time the pack is switched on. Tape or place a wirenut over the end of the white wire to prevent it from coming into contact with +12VDC again.

5. OPTIONAL: If you wish to utilize your own remote pattern select switch, you may connect the white wire to +12VDC through a momentary on/off switch (user supplied).

14. Doubleflash Right†

15. Quadflash Center Out †

16. Quadflash Warning†

17. Pseudo-Random

18. Delta Omega Sweep

19. Alternating Quadflash & Alternating Single flash Combo

20. Delta Om ega Sweep, Alternating Quintflash & Alternating Doubleflash Combo (DEFAULT)

21. Alt. Doubleflash, Simultaneous Doubleflash, Leadfoot, Pseudo-Random & Alt. Quadflash Combo

22. Alternating Climber, Double-Duty, Alternating Quintflash & Alternating Quadflash Combo

23. Cycle Through Patterns 1 - 10, 17 & 18

24. Cycle Through All Patterns

† - Traffic Director type patterns - with only two heads

enabled, these patterns will all be Quadflash Warn.

-8-

BLACK

CONNECT TO +12 VDC

FUSE

15 AMP

312

(High Power Only)

HIGH/ON

Three-Pair Independent Switching

SP3860-3 LIGHTED SWITCH PANEL (REAR VIEW)

213

OFF

LOW/OFF

SW1

SW2

SW3

RED

BLUE

ORANGE

RP966/RP996

GOOD

CHASSIS

GROUND

CONNECT TO +12 VDC

FUSE

15 AMP

GOOD

CHASSIS

GROUND

RED

WHITE

BLACK

PAK

INTO

PLUGS

POWER

SW1 will enable heads 5 & 6

SW2 will enable heads 1, 2, 3, & 4

SW3 will switch between High and Low Power

SW1 will enable heads 5 & 6

SW2 will enable heads 3 & 4

With the Jumper in the High /Low Option Position

(With High/Low Option)

SW3 will enable heads 1 & 2

With the Jumper in the 3-Pair Head Select Position

ENABLE

Two-Head/Four-Head Switching

CONNECTOR

BLACK

WHITE

RED

PAK

INTO

PLUGS

POWER

CONNECTOR

Pattern Select:

Touch and release to +12VDC

to set pattern then tape off

-9-

will be sitting for extended periods of time (i.e. more than a few days), it is recommended that all +12VDC wires

be routed through an ignition switched power source.

Please Note: When the red POWER wire is connected to +12VDC the pack will draw a small current (50 mA). If your vehicle

1. The RP966 and RP996 power packs come with a built-in “star-shaped” status LED.

Status LED

2. When operating properly, the LED will blink in conjunction with each of the strobe heads.

3. If none of the heads are flashing and the Star LED is a dim steady burn, proper voltage is reaching the POWER cable, but is not reaching the ENABLE cable. Check that your switches are on and that +12VDC is reaching the ENABLE wires.

4. The Star LED is also designed to flicker when there are no active strobe heads flashing during a particular flash cycle. If none of the heads are flashing and the LED is flickering, all of the heads are bad or they are all wired incorrectly.

5. If none of the heads are flashing and the Star LED single flashes every 1 -3 seconds then the pack is receiving insufficient voltage (below 11.0 volts).

-10-

Remote Power Pack Cabling Requirements

Length (ft)

Shielded Cable

SO Cable

Length (ft)

Shielded Cable

SO Cable

1. Cable is required to connect the power pack to your remote strobe heads. Cable can be purchased from Star:

w/Amp w/Weatherproof Connector Connector

15 4415 3814-180” 20 4420 3814-240” 25 4425 3814-300” 30 4430 3814-360”

35 N/A 3814-420”

w/Amp w/Weatherproof Connector Connector

40 N/A 3814-480” 45 N/A 3814-540” 50 N/A 3814-600” 55 N/A 3814-660”

60 N/A 3814-720”

2. If you intend to use your own cable for connecting the remote heads, it must meet the following specifications: It must be three-conductor with 600V insulation, it must be a minimum 18 AWG for 0-30 ft. or 16 AWG for 31-60 ft., and it should be UV stabilized. Star does not recommend the use of any cable length greater than 60 feet, as the resistance may cause a drop in voltage resulting in inconsistent or complete loss of firing in the heads. Please use the Table below for proper cable sizes.

Input Power and RP966:

Ground Wires RP996:

0-20 ft. 21-30 ft. 31-60 ft

Wires to

Remote Heads

Enable Wires

16 AWG 14 AWG

18 AWG 18 AWG 16 AWG 18 AWG 18 AWG 18 AWG

14 AWG 12 AWG

12 AWG 10 AWG

3. If you are using your own cable and need connectors to attach the cable to the power pack, order part #CK473. The #CK473 consists of one connector (30041 -20) and three male terminals (30042-16). This is also the replacement connector for any remote heads with the white AMP connectors (NOT weatherproof).

4. The AMP connector, found on the cables, which mates to the CK473 is a kit #CK472. The #CK472 consists of one connector (448) and three female terminals (30042-15).

5. If you need a weatherproof connector kit for your cable to attach to our remote strobe heads, please order part #CK702. This kit contains one connector (30185-3), three female terminals (30042-30), and three rubber seals (30186-2).

6. If you need to order a weatherproof connector kit for your strobe head to mate with the connector on your cable (#CK702), please order part #CK703. This kit contains one connector (30185-4), three male pins (30042-29), and three rubber seals (30186-2).

7. For good, reliable connections between the cable system and the strobe heads in various weather and contamination conditions, it is strongly recommended that dielectric grease be used on the connectors. It should be applied to the rear of the connectors, where the wires enter, as well as into each terminal area where the connectors mate, before joining the two connectors together. We have found this procedure to be effective even under the most extreme of conditions. Do Not Seal

The Connectors Using Silicon Or RTV.

Connecting the Remote Heads:

-11-

If a problem exists in only one head, a strobe tube may have burned out, or there may be an open electrical connection in the wiring harness or strobe head. Check connections at and between the strobe pack and the strobe head, including all wiring. Replace the malfunctioning heads and/or wiring harnesses if necessary.

If none of your heads are flashing, follow these steps to determine the problem:

1. Check all fuses, including those at the battery, at the switch panel, in the dash, and on the pack (if applicable). The RP966 and RP996 have automotive “blade” type fuses. 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 .

2. Check the power and ground wires to your pack. With the vehicle turned off and while the pack is running, measure the voltage across the red wire (pin 1) and the black wire (pin 2) of the POWER connector on the strobe pack. Push the probes of the test meter down into the connector at the wire entry points to contact the terminals for the measurement. A nominal 13.8 volts should be present. Low voltage to the pack can cause erratic flashing or even complete failure of the heads. A minimum of 11.0 volts should be present for the pack to operate properly.

If you do not have proper voltage present your power or ground is bad. Skip

to the section on Checking a Bad Power or Ground Connection.

If your pack is receiving sufficient voltage then continue to step 3.

3. Check the Power connector to be sure that +12VDC is not applied to the white wire. The white wire is used for pattern select. The patterns are changed by touching AND RELEASING this wire to +12VDC. A constant voltage applied to the white wire on the Power connector will prevent the strobe pack from flashing.

4. Check that the proper voltage is reaching the necessary ENABLE inputs.

The black and red wires on the ENABLE plug should have +12VDC. The

white wire should also have +12VDC if the jumper is set for 3-Pair Head Select (see pages 4 and 9).

TROUBLESHOOTING GUIDE

-12-

5. Check each head. 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 each good head should function properly when connected by itself. 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.

Checking a Bad Power or Ground Connection

If sufficient voltage is not reaching the pack, perform the following tests:

1. Test Power at the Battery: With the vehicle turned off and while the pack is running, measure the battery voltage at the battery. A nominal 13.8 volts should exist. If this voltage is below 11.0 volts, the pack will not function properly and the problem is with the battery. This reading should not be more than 1.25 volts higher than the reading at the strobe pack itself.

2. Test the Power Wire Between the Battery and the Switch: Move to the ON/OFF switch in the cab and gain access to the rear of the switch panel. With the vehicle not running and the pack on at the high power setting, measure the voltage drop in the red wire by taking a read ing with one probe on the positive side of the battery and the other probe in 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. NOTE:

Excessive voltage drop may be occurring in the connections on the switch panel. If you have one of our switches you can increase the contact pressure by removing the FASTON terminal from the tab on the switch. Using long nose pliers, gently squeeze the FASTON terminal together in the area that slides on to the tab of the switch. This will increase the pressure applied between the tabs and the connector and reduce voltage drop.

3. Test the Power Wire Between the Strobe Pack and the Switch: This same procedure can be used to check the wires between the switch panel and the pack. Place one probe on the terminal at the switch and the other probe into the terminal with the corresponding wire color in the PWR connector on the pack. Once again, if any of the readings exceed 0.25 volts then you should check those wires and their connections.

4. Test your Ground Wire: If you still have not located the problem, troubleshoot the connections between the good chassis ground and pin 2 (black or blue wire) of the PWR connector on the power pack. With the vehicle not running and the pack on at the high power setting, measure the voltage drop in the Black (Ground) wire by taking a reading with one probe on the negative side of the battery and the other probe in pin 2 of your PWR connector. If this reading exceeds 0.25 volts then you have a bad Ground.

-13-

ONE 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 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.

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 this 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 product,

please contact our Customer Service Department at (585) 226-9787.

If a product must be returned for any reason, please contact our Customer Service Department to obtain a Returned Goods Authorization number (RGA #) before you ship the product to Star.

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

-14-

MODEL ST415P*

These are HIGH INTENSITY strobes. DO

permanent eye damage may occur.

The ST415P series strobe heads are designed for use as an auxiliary warning light system. They will not replace your current headlights or Stop-Tail-Turn lights, but instead will provide an independent, supplementary warning signal.

SAFETY MESSAGE TO INSTALLERS

People’s lives depend on your safe installation of our products. It is important to read, understand and follow all instructions shipped with our products. In addition, listed below are some other important safety instructions and precautions you should follow:

• To properly install this warning light: you must have a good understanding of automotive electrical procedures and systems, along with proficiency in the installation and use of safety warning equipment.

• When drilling into a vehicle structure, be sure that both sides of the surface are clear of anything that could be damaged.

• DO NOT install equipment or route wiring or cords in the deployment path of an air bag.

• DO NOT attempt to activate the light while driving in a hazardous situation.

• File this instruction sheet in a safe place and refer to it when maintaining and/or

reinstalling the product.

Failure to follow all safety precautions and instructions may result in property damage, serious injury, or death to you or others.

REMOTE STROBE HEAD INSTALLATION

3 2

ST415P*

ST415P*-W

IMPORTANT: Please read all of the following instructions before installing your new remote strobe system.

NOT stare directly into the light while it is on, as momentary blindness and/or

PLITSTR346 REV. C 11/1/06

1. The remote strobe head must be connected to a power pak to operate. You may use our two-outlet, four-outlet, or six-outlet paks. These heads may or may not work with alternate brand power paks. The installer accepts any and all liability if this head is used in conjunction with any unapproved power paks.

2. Locate the light housing you wish to install the head into. If necessary, disassemble the light housing on the vehicle such that you can gain access to the back of the reflector.

3. Select a location suitable to mount your strobe head. The ideal location is as close to the focal point of the reflector as possible. The strobe head must be located at least 1” from any other lights, the lens, and the lens housing, to allow for adequate heat dissipation.

4. After you have checked that both sides of the mounting surface are clear, drill a 1” hole in the reflector. Be sure to debur both sides of the hole to allow for easier insertion and so that there is a clean, smooth surface for the strobe head to seal against. If you have a double walled housing (ie. an outer wall in addition to the inner reflector wall), you will need to drill through both surfaces to properly mount your new strobe head. Using a hole saw, drill a 1 1/4" hole in the outer wall. Once through the outer wall, the pilot drill bit from the hole saw should start the pilot hole in the inner wall. Using the pilot hole for centering, drill a 1" hole in the inner wall. Be sure to de-bur both sides of the hole to allow for easier insertion and so that there is a clean, smooth surface for the strobe head to seal against. It might be necessary to cover the 1 1/4" hole you drilled in the outer wall to prevent contaminates getting inside the housing.

5. To insert the strobe head, hold the rubber base with your thumb and forefinger. Slowly twist the base while you push it into the 1” hole. Twisting while pushing helps the cup to slide into the hole easier and helps ensure the lip on the rubber base “pops” into place around the rubber housing.

6. Once the strobe head is installed, reassemble the light.

7. Attach the enclosed connector to the head by snapping the terminals on each wire into the proper slot. Review the diagram below.

BLACK (GROUND)

WHITE (TRIGGER)

BLACK (GROUND)

WHITE (TRIGGER)

RED (HOT)

GROMMET

RED (HOT)

30042-2930186-2

MALE

TERMINAL

30042-16

MALE

TERMINAL

473

FEMALE AMP CONNECTOR

30185-4

FEMALE WEATHERPROOF

CONNECTOR

8. Once the installation of the heads is complete, connect them to your power pak using the proper cable:

Amp Connector Weatherproof Connector

Light Duty Cable 3821 3820 Heavy Duty Cable N/A 3814 Shielded Cable 4415 N/A

9. If you intend to use your own cable, it must meet certain specifications as follows: It must be three-conductor with 600V insulation, minimum 18 AWG for 0-20 ft., 16 AWG for 21-30 ft. or 14 AWG for 31-60 ft. We do not recommend the use of any cable length greater than 60 feet, as the resistance might cause a drop in voltage resulting in inconsistent or complete loss of firing in the heads.

10. For good, reliable connections between the cable system and the strobe head in various

3), three

CK703

FEMALE

MALE

CK472

weather and contamination conditions, it is strongly recommended that a dielectric grease be used on the connectors. It should be applied and into each terminal area where the connectors mate, before joining the two connectors together. We also recommend applying dielectric grease to the back of each connector where the wires enter. We have found this procedure to be effective even under the most extreme of conditions. Do Not

Seal The Connectors Using Silicon Or RTV.

11. If you must remove the white amp connector for any reason, please re-insert the wires back into their proper location. Please refer to the diagram below. If you need to order another amp connector kit, please use part #CK473. This kit contains one connector (473) and three male pins (30042-16).

473

FEMALE

CONNECTOR

3 2

30042-16

MALE

TERMINAL

CK473

RED (HOT)

BLACK (GROUND)

WHITE (TRIGGER)

12. If you need to order a white amp connector kit to mate with the CK473 (the connector on your strobe head), please use part #CK472. This kit contains one connector (448) and three female pins (30042-15).

448

30042-15

WHITE (TRIGGER)

BLACK (GROUND)

RED (HOT)

13. If you must remove the weatherproof connector for any reason, please re-insert the wires back into their proper location. Please refer to the diagram below. If you need to order another weatherproof connector kit, please use part #CK703. This kit contains one connector (30185-4), three male pins (30042-29), and three rubber seals (30186-2).

30185-4

FEMALE WEATHERPROOF

CONNECTOR

30042-29

MALE

TERMINAL

30186-2

GROMMET

BLACK WHITE

RED

(HOT) (GROUND) (TRIGGER)

14. If you need to order a weatherproof connector kit to mate with the CK703 (the connector on your strobe head), please use part #CK702. This kit contains one connector (30185female pins (30042-30), and three rubber seals (30186-2).

30185-3

MALE WEATHERPROOF

CONNECTOR

30042-30

FEMALE

TERMINAL

CK702

30186-2

GROMMET

RED (HOT) BLACK (GROUND) WHITE (TRIGGER)

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. The manufacturer assumes no responsibility for the integrity of the installation for this or any of its products.

CK473

1. Enclosed you will find a kit containing 1 cable-side connector and 3 male pins.

2. Cut off the old connector from the cable on your vehicle, if present.

3. Strip 1½"-2" of the outer insulation off exposing the three inner wires.

4. These wires should be stripped each about ¼".

5. Secure each terminal by crimping the large tabs around the insulation and the small tabs around the exposed wire.

6. After checking that your crimps are secure, insert the terminals into the correct holes in the connector as shown above.

473 30042-16

FEMALE

CONNECTOR

TERMINAL

MALE

7. For good, reliable connections between the cable system and the strobe tube head in various weather and contamination conditions, it is strongly recommended that a dielectric grease be used on the connectors. It should be applied and into each terminal area where the connectors mate, before joining the two connectors together. We have found this procedure to be effective even under the most extreme of conditions. Do Not

Seal The Connectors Using Silicon Or RTV.

RED OR GREEN (HOT)

BLACK OR BLUE (GROUND)

WHITE (TRIGGER)

PLITSTR133 REV. B 11/24/04

CK473

1. Enclosed you will find a kit containing 1 cable-side connector and 3 male pins.

2. Cut off the old connector from the cable on your vehicle, if present.

3. Strip 1½"-2" of the outer insulation off exposing the three inner wires.

4. These wires should be stripped each about ¼".

5. Secure each terminal by crimping the large tabs around the insulation and the small tabs around the exposed wire.

6. After checking that your crimps are secure, insert the terminals into the correct holes in the connector as shown above.

473 30042-16

FEMALE

CONNECTOR

TERMINAL

MALE

Seal The Connectors Using Silicon Or RTV.

RED OR GREEN (HOT)

BLACK OR BLUE (GROUND)

WHITE (TRIGGER)

PLITSTR133 REV. B 11/24/04

CK473

1. Enclosed you will find a kit containing 1 cable-side connector and 3 male pins.

2. Cut off the old connector from the cable on your vehicle, if present.

3. Strip 1½"-2" of the outer insulation off exposing the three inner wires.

4. These wires should be stripped each about ¼".

5. Secure each terminal by crimping the large tabs around the insulation and the small tabs around the exposed wire.

6. After checking that your crimps are secure, insert the terminals into the correct holes in the connector as shown above.

473 30042-16

FEMALE

CONNECTOR

TERMINAL

MALE

RED OR GREEN (HOT)

BLACK OR BLUE (GROUND)

WHITE (TRIGGER)

Seal The Connectors Using Silicon Or RTV.

PLITSTR133 REV. B 11/24/04

CK473

1. Enclosed you will find a kit containing 1 cable-side connector and 3 male pins.

2. Cut off the old connector from the cable on your vehicle, if present.

3. Strip 1½"-2" of the outer insulation off exposing the three inner wires.

4. These wires should be stripped each about ¼".

5. Secure each terminal by crimping the large tabs around the insulation and the small tabs around the exposed wire.

6. After checking that your crimps are secure, insert the terminals into the correct holes in the connector as shown above.

7. For good, reliable connections between the cable system and the strobe tube head in various weather and contamination conditions, it is strongly

473 30042-16

FEMALE

CONNECTOR

TERMINAL

MALE

recommended that a dielectric grease be used on the connectors. It should be applied and into each terminal area where the connectors mate, before joining the two connectors together. We have found this procedure to be effective even under the most extreme of conditions. Do Not

Seal The Connectors Using Silicon Or RTV.

RED OR GREEN (HOT)

BLACK OR BLUE (GROUND)

WHITE (TRIGGER)

PLITSTR133 REV. B 11/24/04

POWER OUT:

POWER PAK

CONNECT TO THE

RED WIRE FROM

CONNECT

TO +12 VDC

(REAR VIEW)

CHASSIS

CONNECT

GROUND

TO A GOOD

Chassis Ground.

1. Connect Terminal 1 shown in the above picture to a Good

wire which supplies power to your power pak.

2. Connect Terminal 2 shown in the picture above to the Red

3. Connect Terminal 3 to your +12 VDC power supply.

on. If you would like to have the switch constantly lit swap the

hook-ups to Terminal 2 and Terminal 3.

4. The above instructions will light the switch when it is turned

POWER OUT:

POWER PAK

RED WIRE FROM

CONNECT TO THE

CONNECT

TO +12 VDC

(REAR VIEW)

CHASSIS

CONNECT

GROUND

TO A GOOD

Chassis Ground.

1. Connect Terminal 1 shown in the above picture to a Good

wire which supplies power to your power pak.

2. Connect Terminal 2 shown in the picture above to the Red

3. Connect Terminal 3 to your +12 VDC power supply.

on. If you would like to have the switch constantly lit swap

the hook-ups to Terminal 2 and Terminal 3.

4. The above instructions will light the switch when it is turned

REV. - 7/12/02 PLITSTR280 REV. - 7/12/02 PLITSTR280

Star Headlight & Lantern RSK996P User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual