Star Headlight & Lantern TD93DLXT User Manual

INSTALLATION AND INSTRUCTION MANUAL

TRAFFIC DIRECTORS

TD92

TD93

TD93DLXT

TD93DLXT24

PLITSTR241 REV. H 8/31/12

Important

: This product is used to direct traffic. Improper use may
result in vehicular collision, personal injury and/or death. Star
Headlight & Lantern Co., Inc., and its subsidiaries shall not be held
responsible for damages directly or indirectly caused by improper use
of this product. Always carefully consider the effect on traffic that the
selected light pattern will have before engaging the lights.

Before beginning the installation:

- Determine where the Traffic Director is to be mounted (on your lightbar, on
your roof, in your rear window, etc.

- Check to see that there are no obstructions hindering the visibility of your
traffic director.

- Then select a location to mount your controller. The controller must be
located in a dry location out of direct sunlight, free of dirt and dust. Under the
vehicle's instrument panel is usually the best choice.

- Once you have selected these locations, determine the path your cable,
which connects the controller to the Traffic Director, will take. The cable
should exit the left side of the Traffic Director when you are facing both the
stick and the controller.

Depending upon the specific model number, the TD92 and TD93 series come
with either a 15’, 30’, 45’, or 60’ cable pre-installed.

The TD93DLXT series come with a short pigtail out of the side of the light that
attaches to the main harness. The available lengths for the harnesses are 15',
30', 45', and 60'.

Be sure the harness attached to your Traffic Director is long enough for proper
installation. Star does not recommend “splicing in” additional cable when
the supplied cable is too short. If it is too short, you will need to order a
Traffic Director with the correct length cable pre-installed (TD92 and TD93), or
you will need to order a harness of the correct length (TD93DLXT).

-i-

TD77

7

2

8

"

2"

1

1

"

4

15

3

16

"

TD92

3
4

"

"

3
4

"

1

1

"

8

1

1

"

2

1

7

16

2

TD93 / TD93DLXT

13

27

32

1

"

1

13

32

32

"

1

1

"

8

9

"

16

"

1

1

2

-ii-

"

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.

Mounting Instructions

Please Note: These instructions are provided as a general guideline only. Some
vehicles may require special mounting, wiring, and/or weather-sealing. This is 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.

1. Caution: There are two vapor vent holes drilled in the bottom slot of the TD92. Check
the extrusion for these holes to be sure they are located at the bottom when you mount
the bar.

2. Each bar light assembly comes equipped with slots along the entire length of the
extrusion that will retain ¼” hex head bolts. The TD92 has slots along the top, bottom,
and rear. The TD93 and TD93DLXT only have slots along the rear.

3. Two “L”-Brackets are included with each traffic director to assist in mounting it to a
lightbar or other secure base. The #TD77-6K L-Bracket Kit is shipped with the TD92.
The 274-LLBK L-Bracket Kit is shipped with the TD93 and TD93DLXT.

NOTICE

TD77-6K

274-LLBK

4. Also included are four ¼” x 20 x ¾” hex head bolts, four flat washers, four split washers,
and four nuts to attach the L-Brackets to your traffic director. You can mount your traffic
director directly to your vehicle using the enclosed bolts or your own ¼“ hex head bolts.
You may also use the enclosed hardware to mount the L-Brackets to your traffic director.

-1-

(Mounting CONT’D)

5. Models with endcaps have the bolts
pre-installed. The additional bolts
enclosed in the hardware kit will not be
needed.

If yours are NOT installed, slide the
necessary number of bolts into the
appropriate channels on your traffic
director.

6. Slide the bolts to their desired location along the tracks and mount the bolts through pre­drilled holes in your vehicle or mounting bracket. Use a flat washer, split washer, and
nut on the bolt. If you are using the L-brackets provided, you will need to supply
appropriate bolts or other fasteners to attach the brackets to your mounting surface.

Slide the bolt

heads into the

appropriate

slots.

Mount directly
to mounting
surface

OR

Mount to
enclosed
L-Brackets

CAUTION: Be sure to carefully inspect and test the

integrity of your mount.

Because of the wide variety of mounting applications,
Star Headlight & Lantern Co., Inc. assumes no
responsibility for the secure mounting of this light. It is
the responsibility of the installer and/or owner to ensure
the lightbar is mounted securely. Check your light
every time you use the vehicle to ensure that it is
mounted securely.

-2-

Electrical Connections

Please note: If you are connecting a TD93DLXT24 (which operates only on 24VDC) the

Input Power (and bypass power) would be 24VDC in the diagram above.

1. The cable attached to your Traffic Director should have a green connector (part #CPSS-153)
attached to it. Eight colored 18 AWG wires, one bare drain wire, and a large red 12AWG wire
should already be connected from the cable to the connector.

2. Connect a ground wire to the interior empty terminal on the green connector.

above)

The corresponding terminal plugs into the outlet on the back of the controller and is

marked

BAT-

.

It is imperative that you supply a ground wire to the terminal marked

(See diagram

"BAT -" on the controller. You must not let the controller's case supply

3. Supply power for the unit from a

ground. Use 12 AWG wire for all power and ground connections

fused,

+12 VDC source (or 24VDC for the
TD93DLXT24) capable of delivering at least 15 amps of current (use a 20 amp fuse).
Star recommends the use of an ignition switched supply to avoid the possibility of
draining the vehicle's battery should the unit be accidentally left on.

4. Connect your power supply to the terminal on the green connector that corresponds to
the outlet on the back of the controller marked

BAT+

.

5. The lamp brightness will be somewhat diminished if a large voltage drop exists between
the vehicle's battery and the controller. If voltage drop is a problem, use a relay to
control a direct battery feed. A generic relay designed for automotive lamp service
should be available from most automotive stores for this purpose. If using a relay, don't
forget to

fuse the feed and signal wires

imperative that you supply a ground wire to the terminal marked "
controller; you must
power and ground connections.

not

let the controller's case supply ground. Use 12 AWG wire for all

at their source, with appropriate values. It is

BAT -

" on the

6. Your Traffic Director should now be ready to operate.

-3-

(Wiring CONT’D)

Wiring for Optional Automatic Activation

1. The Traffic Director may also be wired to automatically bypass the TD77-2 (or TD77-2-24)
controller On/Off switch and turn on through the use of an alternate power source (i.e. lightbar
switch, siren switch, reverse switch, etc.).

2. When you apply +12VDC to the 12AWG wire supplying the stick with power, you will bypass
the On/Off switch and activate the Traffic Director. When activated, the Traffic Director will
automatically enter the "Warn" pattern.

Please note: If any other lights are connected to
this “bypass” circuit they will activate any time the traffic director is powered up unless
they are isolated in some way (e.g. diode or relay).

Please note: If you are connecting a TD93DLXT24 and TD77-2-24 (which operate only

on 24VDC) the bypass power would be 24VDC in the diagram above.

Jumper Settings

The TD77-2 control box and the ULB42-TD-2
control box are identical except for the factory
default setting of a jumper located inside the
control box. This jumper will control the output of
the two arrays on each end. The TD77-2 comes
with the jumper defaulted for standard operation.

Optionally you may wish to set the jumper so that your arrowstick operates in "Phantom" mode. In
the “Phantom” mode, the end lights are not part of the “traffic directing” patterns. When the Alt
button is pressed, both of the end lights will flash back and forth in a “warn” type display. (In the
"standard" mode, the end lights will follow the normal “traffic directing” pattern you select on the
control box.) If you wish to operate your traffic director in Phantom Mode, (6-head traffic directing),
follow the instructions below to remove the cover and change the jumper setting. If the standard
mode is acceptable, skip this section.

When the control box jumper is in the "Phantom Mode" setting (see diagram on next page)

only the center 6 arrays will be utilized during the Left, Center Out, and Right patterns.

The outer two heads or arrays will flash alternately.

TD77-2 or TD77-2-24

-4-

((Jumper Settings CONT’D)

Arrow stick Control Box Cover Removal

Remove the four recessed Philip head screws (two on each
side of the arrow stick control box). Remove the top cover
by sliding it towards the front of the unit.

TD77-2 and ULB42-TD-2 Controllers

Locate the extra jumper
location near the fuses. Move
the jumper from the “Option”
jumper location near the center
of the board over to the extra
jumper section. (See diagram
below).

Jumper moved to

extra jumper holder

from 1st pair of pins

for Phantom Mode

For standard operation (8-light

traffic directing), the first jumper

remains in the TD77-2 spot

TD77-2

Operation

Important: This product is used to direct traffic. Improper use may

result in vehicular collision, personal injury and/or death. Star
Headlight & Lantern Co., Inc., and its subsidiaries shall not be held
responsible for damages directly or indirectly caused by improper
use of this product. Always carefully consider the effect on traffic
that the selected light pattern will have before engaging the lights.

1. Your new traffic director is a powerful tool that can aid you in traffic control; or if used

improperly

USE CAUTION!!!

2. Operation of your Traffic Director is
straightforward. The controls
include an

Pattern Select

additional "option" buttons.

3. Turn the vehicle's ignition switch to the on or accessories position to supply power to the
controller (if necessary) and press the On/Off switch on the control box. The LED
display should begin to show the "Warn" pattern and the "Warn" label should glow red.

, it could direct traffic into a

On/Off

switch, four

buttons, and three

dangerous situation.

TD77-2 or TD77-2-24Controller

-5-

(Operation CONT’D)

4. Select the desired pattern (if different from the current pattern)
by using any of the

Select

buttons include

Pattern Select

Left, Center, Right,

buttons. The

and

Pattern

Warn

. The
selected pattern label should change to red and the light
output should mimic exactly the display on the controller.

5. The TD77-2 series controllers also have three "option" buttons:
Fast, Dim, and Alt.

Dim Button

This Traffic Director has three different levels of “brightness”. This
allows the user the option to dim the light for nighttime operation.
When the "Dim" button is pressed once the "Dim" label will change from green to red
and the Traffic Director will dim slightly (50%). Pressing it a second time will change the
button to orange and the traffic director will dim further (15%). Pressing it a third time
will return the Traffic Director to full brightness.

Alt and Fast Buttons
The Alt and Fast buttons have a different effect on the Left, Center Out, and Right
patterns than the effect they have on the Warn pattern.

Alt Function for Left / Center Out / Right Directional Patterns

Note: The options described below only apply if you have your controller in Standard Mode. If

you set the jumper for Phantom Mode (as described on page 4) the Alt button will only

When your controller has the jumper set for Standard Mode

have the
eleven different alternate
three directional patterns and will remain selected even if the unit is powered off.

enable or disable the two outer flashing arrays/heads and you should skip to the next page.

(default), and when you

Left, Center-Out

•

The first four versions (A-D) are 7-light versions designed for use with traffic
directors that may have an arrow painted on each end.

•

The next four (E-H) are the same as the first four, but utilize all eight lights.

•

I and J provide two additional 8-light versions.

•

The final version (K) uses only the center six lights. The outer two lights are rapidly

, or

Right

versions

pattern selected, the "Alt" button will scroll through

of that pattern. The version selected will apply to all

flashed (similar to Phantom mode).

7-Light Patterns

A. Progressive 7 - Starts with one light and consecutively adds lights to the pattern until they

B. End Blink 7 - Same as the Progressive 7 version with the exception that the last light will

C. Dual Light 7 - Only two lights will be lit at the same time. The two lights will "roll" in the

D. Progressive 7 T13 - Superfast Progressive 7

8-Light Patterns

E. Progressive 8 - Same as the 7-Light version above, except all 8 lights are used.

F. End Blink 8 - Same as the 7-Light version above, except all 8 lights are used.

G. Dual Light 8 - Same as the 7-Light version above, except all 8 lights are used.

H. Progressive 8 T13 - Superfast version of Progressive 8

I. Quad Light 8 T13 - 4-Head rolling version

J. Snake 8 T13 - 8-head rolling version (aka Progressive On, then Progressive Off)

(California Title 13 and SAE compliant *)

6-Light Pattern

K. Outer Flashing - Same as the Progressive pattern, but only uses the six center lights. The

* When used with an approved lightstick

are all lit. The first light (usually in the shape of an arrow) will not
illuminate.

double blink.

direction of the selected pattern. The first light will not illuminate in this
pattern.

(California Title 13 and SAE compliant *)

(California Title 13 and SAE compliant *)

(California Title 13 and SAE compliant *)

.

outer two light alternate quickly back and forth.

-6-

(Operation CONT’D)

Fast Function for Left / Center Out / Right Patterns

The "Fast" button provides the user with the option to display any of the patterns (Left,
Center Out, or Right) in a "faster" mode. Pressing the "Fast" button once should
change the "Fast" label to red and speed up the pattern. Pressing the button again will
change the "

Fast

" label back to green and revert the pattern to the standard speed.

Alt and Fast Functions for Warn Pattern (Standard Mode Only)

When the Traffic Director is in the Warn pattern, the Alt button will scroll through 10

different versions. The 10 versions differ depending upon if you have the Fast button
activated or not. Review the chart below for the different versions that can be scrolled
through.

Fast Button De-Activated Fast Button Activated

1. 6-Head Warn Pattern 1. 6-Head Random 1 †

2. 6-Head Warn w/Alternating Ends 2. 6-Head Warn w/Alternating Ends

3. 8-Head Warn 3. 8-Head Random 2 †

4. Search Light 4. Search Lights †

5. Side Band Alternate 5. Side Band Alternate †

6. Random 1 † 6. Hyper Random 1 †

7. Random 2 † 7. Hyper Random 2 †

8. 8-Head Warn T13 † 8. 8-Head Warn T13 †

9. 8-Head X T13 † 9. 8-Head X T13 †

10. 8-Head Jumble † 10. 8-Head Jumble †

† - These patterns are not recommended for use with the TD77 or other incandescent traffic directors
T13 - California Title 13 and SAE compliant patterns when used with approved sticks

These Traffic Directors have 8 LED arrays.

6-Head WARN patterns only utilize the center 6 arrays

6. When using the Traffic Director, always be sure that the pattern selected is appropriate

for the present hazard condition.

inappropriate pattern cannot be overstated.

The potential danger in displaying an

7. To avoid possible damage, the controller should be turned off prior to engine starting.

It is possible, though not likely, to confuse the controller if the vehicle's battery is low
and the engine is started with the controller running. If you notice that the controller's
display shows something out of the ordinary, simply push the power switch to the off
position and back on again. This should clear any fault caused by improper voltage
being supplied to the unit.

Once your Traffic Director is installed, please test all the patterns, options, and alternate versions to
familiarize yourself with the various patterns and the operation of the controller.

-7-

Replacement Parts

These traffic directors all use state-of-the-art light Emitting Diode (LED)
technology. These lightsticks are comprised of eight segments of Ultra-Bright
LEDs that are operated in a multiplexed mode to efficiently produce light
output with lifetimes up to 100,000 hours. Under normal circumstances, you
will not need to replace any lights in these lightsticks.

TD92 and TD93

If any of the LED's in your lightstick do fail, please contact the factory for arrangements to
have them repaired.

TD93DLXT and TD93DLXT24

The TD93DLXT series are designed such that if there is a failure in one of the arrays, the
array can easily be replaced without removing the lightstick from the vehicle. The
replacement head is a part #TD93DLXTRH-* or TD93DLXT24RH-* (*=color).

TD77-2 Series Controllers

The TD77-2 controller, used with all of the traffic directors, contains two ATO "blade-type"
fuses located in the back of the controller. The fuses are accessible from the rear of the
controller. The 20 amp fuse controls power to the bar light assembly, while the 5 amp fuse
powers the controller. If the 20-amp fuse blows the controller will continue to function
normally, however, the roof lamps will not. It is important to note that under normal
circumstances the only reason a fuse will blow is because there is a fault in the system.

a fuse blows repeatedly it is a signal that something is wrong.

Do not replace a blown

If

fuse with anything other than the same amperage rating as marked on the rear panel of
the controller; doing so may damage the unit, or worse yet start a fire. Likely causes of
blown fuses are improper wiring, harness damage, and/or improper bulb type.

-8-

LED FIVE YEAR LIMITED WARRANTY

The manufacturer warrants this LED 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. Exclusions from this
warranty include, but are not limited to, 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.

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 con sequential 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 [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 back.

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

-9-