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2562099BREV. B 1006Printed in U.S.A.
INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR
SMART VECTOR™ SL LED LIGHTBAR
SAFETY MESSAGE TO INSTALLERS AND USERS
WARNING
People’s lives depend on your safe instal-lation of our products. It is important to read, understand and follow all instruc-tions shipped with the products. In addi-tion, listed below are some other important safety instructions and precautions you should follow:
• Toproperlyinstalllightbar,youmusthaveagoodunderstandingofautomotivesystems,alongwithproficiencyintheinstallationanduseofsafetywarningequipment.
• DONOTinstallequipmentorroutewiringinthedeploymentpathofanairbag.
• ThisproductcontainshighintensityLEDdevices.Topreventpermanenteyedamage,DONOTstareintothelightbeamatcloserange.
• Alightsystemisahighcurrentdevice.Inorderforittofunctionproperly,aseparategroundconnectionmustbemade.Ifpracti-cal,itshouldbeconnectedtothenegativebatteryterminal.Ataminimum,itmaybeattachedtoasolidmetalbodyorchassispartthatwillprovideaneffectivegroundpathaslongasthelightsystemisused.
• Whendrillingintoavehiclestructure,besurethatbothsidesofthesurfaceareclearofanythingthatcouldbedamaged.
• LocatethelightsystemcontrolssotheVE-HICLEandCONTROLScanbeoperatedsafelyunderalldrivingconditions.
• Themountingsystemshouldbeperiodicallyinspectedtoensurethatitissecurelyat-tachedtothevehicle.
• Improperlightbaractivationmayoccurifthelightbarisinstalledlessthan18-inchesawayfromatwo-wayradioantenna.En-surethatthelightbarisinstalledatleast18-inchesawayfromanytwo-wayradioan-tenna.
• Filetheseinstructionsinasafeplaceandrefertothemwhenmaintainingand/orrein-stallingtheproduct.
Failure to follow all safety precautions and instructions may result in property damage, seri-ous injury, or death to you or others.
I. GENERAL.
TheSmartVectorSLwarningsystemisafull-featured,programmablehalogen/LEDwarninglightsystem.V-shapedconstructionletstheSmartVectorSLwarningsystemmaximizelightwarningefficiencyatcrucial45°angles.TheLEDpodsaretwo-tierwiththewideangleSolarisLEDspositionedtoprovide360°coverage.Thewarningsystem’stwoSmartPodsarepreprogrammedtoprovideawideselectionofwarninglightpatterns.Availablepatternsinclude:rotateat90,120or175flashesperminute;oscillatetothefront,rear,orintersection;aswellasfrontorrearflashing.Patternselectioncanbeperformedduringorafterinstallation.Take-downandalleylightshavehorizontaltrackingcapabilityforuseasspotlights.AnoptionalLEDreardirectionallight,calledtheSignalMaster™,providesadditionalwarningcapability.TheSignalMastercanbeoperatedviatheinternalcontrollerwithitsprepro-grammedlightpatterns,orbyanexternalcontrollerliketheSS2000SM,SMC16andSMC56SignalMastercontrollers.
II. UNPACKING.
AfterunpackingtheSMARTVECTORSLlightas-sembly,inspectitfordamagethatmayhaveoccurredintransit.Iftheunithasbeendamaged,donotattempttoinstalloroperateit.Fileaclaimimmediatelywiththecarrier,statingtheextentofdamage.Carefullycheckallenvelopes,shippinglabels,andtagsbeforeremovingordestroyingthem.
III. INSTALLATION.
WARNING
Improper lightbar activation may occur if the lightbar is installed less than 18-inches away from a two-way radio antenna. En-sure that the lightbar is installed at least 18-inches away from any two-way radio antenna.
Beforeproceeding,ensurethatthelightbarhasbeeninstalledonthevehicleroofinaccordancewiththeinstructionspackedwiththemountingkit.Thelightbariscompletelywiredatthefactoryanddoesnotrequireanyadditionalinternalwiring.Alltheconductorsneces-saryforcontrolofanyandallbasicandoptionalfunc-tionsarecontainedinthecable.Thebasiclightfunc-tionsoftheunitmustbecontrolledbyauser-suppliedcontrolhead.
WARNING
Light system controls must be located so that the VEHICLE and CONTROLS can be operated safely under all driving condi-tions.
3-1. CONTROL WIRING.
A. Routethecontrolcableintothevehicleandneartheeventuallocationoftheuser-suppliedcontrolhead.RoutethePowercableintothevehicleandtothebattery.
B. Forproperlightoperation,thecontrolcablemustbeproperlyterminatedinsidetheuser-suppliedcontrolhead.
Usingfigure3-1andtable3-1asaguide,maketheappropriateelectricalconnections.Ensurethatthelinesareadequatelyfusedasshownandthattheswitchcapacityisadequateforthecurrentrequire-ment.
CAUTION
Reversepolaritymaydamageanypowersupplyandpreventoperation.Ensurethatthecorrectpolarityisobserved.Thepositive(+)RED10GAwiremustbefusedatthesourcefor40amps.
C. ConnecttheseparateBLK10GAwiretothevehiclebatterygroundterminal(-)andtheseparateRED10GAwiretothevehiclebatteryhotterminal(+).
LIG
HTB
AR
WHT/RED
RED
WHT/ORN
ORANGE
WHT/YEL
YELLOW
GREEN
WHITE
GRAY
WHT/BRN
BROWN
WHT/VIO
VIOLET
WHT/BLU
BLUE
WHT/GRN
WHT/GRY
MODE 3
MODE 2
MODE 1
STEADY BURN RED
INTERSECTION
JOG LEFT
BLACK
WHT/BLK
JOG RIGHT
PROGRAM
RIGHT ALLEY
LEFT ALLEY
TAKEDOWNS
SM INT LEFT
SM INT CENTER
SM INT RIGHT
SM INT WARN1
SM INT WARN2
SM INT WARN3
SM INT WARN4
SPEED
BLK/PNK INGNITION PWR
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
20 COND 22AWG CABLE
40 A
SM EXT (SS2000 8)
SM EXT (SS2000 7)
SM EXT (SS2000 6)
SM EXT (SS2000 5)
SM EXT (SS2000 4)
SM EXT (SS2000 3)
SM EXT (SS2000 2)
SM EXT (SS2000 1)
(SMC BLUE)
(SMC GRAY)
(SMC YELLOW)
(SMC VIOLET)
(SMC ORANGE)
(SMC GREEN)
(SMC BROWN)
(SMC WHITE)
290A5310-01
(+) POWER/IGN
(+) BATTERY
(-) GROUND
Figure 3-1.
NOTE
Allthelightbarfunctionscanbeactivatedbyapplying12VDCtotheappropriatecontrolwire.The10GABLKandREDpowerwiresmustbeconnectedtotheirrespectivebatteryterminalsforafunctioncheck.
3-2. FUNCTION ACTIVATION – EXCLUDING SIGNALMASTER™.
NOTE
Refertotable3-1andfigure3-1forpropercon-nections.
-2-
C0NROLCABLE MAINFUNCTIONS SMINTERNAL S2000/SM SMC16 SMC56
WHT/RED MODE3 MODE3 MODE3 MODE3 MODE3
RED MODE2 MODE2 MODE2 MODE2 MODE2
WHT/ORG MODE1 MODE1 MODE1 MODE1 MODE1
ORG STEADYRED STEADYRED STEADYRED STEADYRED STEADYRED
WHT/YEL INTERSECTION INTERSECTION INTERSECTION INTERSECTION INTERSECTION
YEL JOGLEFT JOGLEFT JOGLEFT JOGLEFT JOGLEFT
BLK/PNK IGNITIONPWR IGNITIONPWR IGNITIONPWR IGNITIONPWR IGNITIONPWR
BLK JOGRIGHT JOGRIGHT JOGRIGHT JOGRIGHT JOGRIGHT
WHT/BLK PROGRAM PROGRAM PROGRAM PROGRAM PROGRAM
GRN RIGHTALLEY RIGHTALLEY RIGHTALLEY RIGHTALLEY RIGHTALLEY
WHT LEFTALLEY LEFTALLEY LEFTALLEY LEFTALLEY LEFTALLEY
GRY TAKEDOWNS TAKEDOWNS TAKEDOWNS TAKEDOWNS TAKEDOWNS
WHT/BRN N/C LEFT (8) BLU BLU
BRN N/C CENTER (7) YEL YEL
WHT/VIO N/C RIGHT (6) GRY GRY
VIO N/C WARN1 (5) VIO VIO
WHT/BLU N/C WARN2 (4) ORG ORG
BLU N/C WARN3 (3) GRN GRN
WHT/GRN N/C WARN4 (2) BRN BRN
WHT/GRY N/C SPEED (1) WHT WHT
Table 3-1.
NOTE
Poweringmultipledeviceswithacommoncon-trolleadmaycauseoneormoreunitstobrieflyremainfunctionalaftersignalpowerisremoved.Forexample,duetothehighinputfiltercapaci-tance,astrobesupplycanbrieflysupplythecurrentrequiredtooperatealowcurrentdevicesuchasanLED.Ifnecessary,usearelaytoiso-latedeviceswithlargefiltercapacitors.Seefig-ure3-2fortheschematic;allcomponents/wiresareuser-supplied.
A. Mode Inputs.
Therearethreeprioritizedmodeofoperationavailablewithmodethreebeingthehighestpriority.Mode3(WHT/RED)willoverrideMode2(RED)andMode2willoverrideMode1WHT/ORN).Oneoftheavailableflashpatternscanbeprogrammedtoeachmodeinput.DefaultconfigurationisMode3RandomFlash,Mode2QuadFlashandMode1SingleFlash.ProgrammingiscoveredinSection3-4and3-5.Toac-tivateamode,apply12VDCtoamodeinputwire.Seefigure3-1forproperfusing.
B. Steady Burn Red.
WhentheSMARTVECTOR™SLisequippedwithaSteadyBurnRedledmodule,applying12VDCtotheOrangewirewillcausethatmoduletooperatewhenanymodeinputisselected.
C. Intersection Mode.
When12VDCismomentarilyappliedtothe(WHT/YEL)wire,itwillcausetheflashrateofthese-lectedmodeinputtodouble.When12VDCisappliedagaintheflashratewillreturntonormal.
D. Right Alley.
Applying12VDCtotheRightAlley(Green)wirewillcausetheRightAlleylightstoilluminate.
E. Left Alley.
Applying12VDCtotheLeftAlley(White)wirewillcausetheLeftAlleylightstoilluminate.
290A5310-02CUDATRIOPTIC
+12VCONTROL LEAD
(12V SIGNAL ACTIVATED)
RELAY
FUSE
STROBE SUPPLY
Figure 3-2.
F. Takedowns.
Applying12VDCtotheTakedowns(Gray)wirewillcausetheTakedownslightstoilluminate.
G. Jog Left.
Applying12VDC(viaauser-suppliedmo-mentaryswitch)totheyellowwirewhilealleysortake-downsareilluminatedwillcausetheSmartPod(s)tosteptotheleft.Iftheswitchispressedandreleased,theSmartPod(s)willjogleftonestep.Iftheswitchishelddown,theSmartPod(s)willcontinuetostepleftuntiltheswitchisreleased
H. Jog Right.
Applying12VDC(viaauser-suppliedmomen-taryswitch)totheblackwirewhilealleysortakedownsareilluminatedwillcausetheSmartPod(s)tosteptotheright.Iftheswitchispressedandreleased,theSmartPod(s)willjogrightonestep.Iftheswitchishelddown,theSmartPod(s)willcontinuetosteprightuntiltheswitchisreleased
3-3. FUNCTION ACTIVATION – SIGNALMASTER.
NOTE
JumpersarefactoryinstalledforExternalSig-nalMasterController.Refertotable3-1andfig-ure3-1forproperconnections.
A. SignalMaster Internal Controller.
1. Seefigures3-3&3-4.Ensurethatjump-ersJP2&JP7areinstalledasindicated
2. When12VDCisappliedtooneofthecontrolwiresthecorrespondingSignalMasterfunctionwillactivate(seetable3-1).Thefirstseveninputsareprioritized,with“Left”(WHT/BRN)beingthehighestpriorityand“Warn4”(WHT/GRN)beingthelowestpri-ority.Thehighestpriorityinputthathas12VDCappliedwilloverrideanyotherinputthathas12VDCapplied.Whenusingathreepositionprogressiveslideswitchfor“Left”,“Center”and“Right”functions,“Left”isconnect-
J17
R30
Q2
+
R40
H3
H2
H4
F7
R55
+ +Q -
F6
J12+P - O - + N -
C28
F5D10
C33
F4
F3
C20
+
Q6
+ D4
+F2
U5
F1
C21
J10
R41
Q8
-J13
+M - L -
U8
+ K - + JJ14GG
HH EFF F HG NM -
U9
UPPER TAKEDOWNSALLEY- -
J15+ +
Q9
J16ORGWHT + SR -
R46
Q7
J11
R29
Q4
ALLEY
J9
A
+C10
D2
-U1
D C B
R6
R15
+
J1BB CC DD
J2+
JP4
MADE IN U.S.A.UNIVERSITY PARK, IL
FEDERAL SIGNAL CORP.
2005245A-
-
J3JJ
Q1
- - - + - KK +
1 2JP3
3
R7 R8
LL + MM- +
R9
NN- + -
GND
LF
H1
NSM
SM
JP5
U2
-OO
J4+ PP + QQ- + -
U3
-
J5+ - LR + -RF + RR +
R20 R22R19 R21
C49D21
RSB
R51 R52
J18
C46
SR+ - J19
C47
C42
D19D18
C43
D20
R53
SIGMAST INPUTSFSB
C48J20
U10
R47
C44
R48
C45
MAIN PROGJ21
R50
JP7
R49
R54 D22
C50
C24
R33R32
D17
D12
D14 D15
D11
D16
U6
D7
D5
D6 D8 D9
C38
R42
C34D13
R43
C39
C35
R36
C29
R37
C30
R31
R17 R18
C22
C16
C23
C17
R25
C11
R26
C12
R35R34
C37
R45
C41
R44
C40
C36
R39R38
C31 C32
1 U7
R24
D3C25
C19C18
C26
R28
C14
R27
C13
JP6
Y1
C15
C27
C9
R23
R16
PATTERN INPUTS
J7RIGHT
ALLEYSRIGHT
TAKEDOWNSLEFT
J6
Q3
LEFT
C5
R11
C6
R12
R1
C1
R2
C2
D1
R5
JP1
C8
R14
C7
R13
JP2
SM PROGRAM
R3 R4
C3 C4
J8
C52C51
U4
R10
290A5310-03
Figure 3-3.
-3-
JP2
JP7
290A5310-04
JP2
JP7
290A5310-05
Figure 3-4.
Figure 3-5.
edtopositionone“Center”topositiontwoand“Righttopositionthree.The“Fast”(WHT/GRY)inputwillcausetheSignalMastertooperateattwicethenormalspeed,when12VDCisappliedtotheinput.
B. SignalMaster External Controller.
1. Seefigure3-5.EnsurethatjumpersJP2&JP7areinstalledasindicated.
2. Refertotable3-1andconnecttheSig-nalMasterinputwirestothecorrespondingconnectionsfortheSS2000/SM,SMC16andSMC56SignalMastercontrollers.
3-4. PROGRAMMING LED FLASH PATTERNS.
Therearethreelightbarmodesthatcanbepro-grammedbytheuser,viathreecontrolinputwires.TherearealsosixavailableLEDflashpatterns:
• Random • QuadFlashalternating75FPM • SingleFlashalternating75FPM • AlternateFlashPOD’s1&790FPMrearonly • AlternateFlashPOD’s1&790FPMfrontandrear • AlternateFlashPOD’s1&7withPOD490FPMrearonly
Threedefaultpatternsareassignedtooperateinslideswitchpositions1,2,and3.Theyareasfollows:
• WHT/ORG-Mode#1–Singleflash • RED-Mode#2–Quadflash • WHT/RED-Mode#3–Random
Tochangeaflashpatternassignedtoaslideswitchperformthefollowing:
A. Activatelightbarinthedesiredslideswitchposition.Thebarwillflashinthecurrentpattern.
B. Momentarilyapply12VDCtotheprograminput(WHT/BLK).TheLEDflashpatternwilladvancetothenextavailablepatternandtheendLEDmoduleinPOD#1willflashtheselectedpatternnumber.Thelightbarwillstopmomentarily,thenoperateintheselectedpattern.Eachtime12VDCismomentarilyap-pliedthepatternnumberwilladvance.Whenthelastavailablepatternnumberisreached,thenextmomen-taryapplicationof12VDCwillselectthefirstavailablepattern.
C. Ifpatternsassignedtotheothermodeinputsaretobechanged,apply12VDCtothedesiredmodein-putandrepeattheabovesteps.
3-5. PROGRAMMING SMART POD PATTERNS.
TherearethreeSmartPodprograminputsplusanOFFpositionthatcanbeassignedtoaslideswitchposi-tion.
1. Off 2. P1 3. P2 4. P3
TheSmartPodsareprogrammableontwolevels.First,eachoftheprograminputs,i.e.,P1,P2,andP3,canbesettodooneofeightavailablepatterns.Seefig-ure3-6.ThesepatternsareselectedusingdipswitcheslocatedontheSmartPodControllerboard.Referto
-4-
1 6
ON
WL
TD 1/2
P3C
P3B
P3A
-+-
R37
R28
J6
R10U4
R36R26
D3
R27
F2 F3+
J5
R9U3
1J4
U2
R25R35
D2
8
R12
1J3
U1
C11
C15
P3A
S1 R34
2R53
D6
1
R52
D5 R40
2005325A-
UNIVERSITY PARK,IL
P1B
P2AP1C
P1A
R39
P2CS21
P2B
1 U6
RN2D11
C16Q5RN1 Q6C17 C18
FEDERAL SIGNAL CORP.
11
7R8R7
R11R20
R6R4 R5
R17R18R19
P3B
P3CWL
1/2C7C5 C6
C13TD
C8 C9
R3R1 R2
R13 R14R15
C4C2 C3
C12Q11
R33
R16
F1 J1 J2
BATT-
H1
C1
1
L1
C14
J8
Q4
8
1
R32L4R31R23 R24
L5
F4
D1
H2
BATT+
D8
D9
R51
C26 D7
C19
+
C22
R38
U5
R50R41
U7 C25
D4
C24C23
C20
C21
L9
Q10
R49
R44
L8
R45
+
Y1L3R30R22
10
Q1
R29R21
Q2
J7
Q9
R43
L7
Q7
L6
R42
R47
Q8
R46
L2
R48
Q3
D10
C10
S1
P1B
P2AP1C
P1A
P2CS2
P2B
6 POS SWITCH
290A5310-06
Figure 3-6.
switchtables3-2through3-4.SeeSection5ServiceandMaintenanceforboardaccessprocedures.Oncepatternsarechosenforeachoftheprograminputs,thenthepro-graminputsareassignedtoaslideswitchposition.
Thedefaultprograminputsassignedtoaslideswitchposition,alongwiththedefaultpatternforeachprograminputareasfollows:
• Slideswitchposition#1–P1,RearFlashing • Slideswitchposition#2–P2,Rotate90FPM • Slideswitchposition#3–P2,Rotate90FPM
ToassignadifferentSmartPodprograminputtoaslideswitchpositionperformthefollowing:
A. Disconnectpowertothelightbar.Ifthecoverisremoved,thiscanbeaccomplishedbyremovingthe10GAREDpowerwirefromtherelay.
B. Apply12VDCtotheWHT/YELandWHT/BLKcontrolwires.
C. Applypowertothelightbar(reconnecttheRED10GApowerwire.)
D. TherightupperLEDmoduleinPOD#4willlightindicatingthebarisinSmartPodprogrammingmode.
E. Movetheslideswitchtothedesiredposition.Thefollowingwillbedisplayedforeachslideswitchpo-sition:
1. SlideSwitch#1–FrontLEDmodulePOD#1andtheSmartPodswilloperateaccordingtothestoredprograminput.
2. SlideSwitch#2–FrontLEDmodulePOD#1,theupperLEDmodulePOD#1andtheSmartPodswilloperateaccordingtothestoredprograminput.
3. SlideSwitch#3-FrontLEDmodulePOD#1,theupperLEDmodulePOD#1,rearLEDmod-ulePOD#1andtheSmartPodswilloperateaccordingtothestoredprograminput.
F. Remove12VDCfromtheWHT/BLKcontrolwire.Momentarilyre-apply12VDCtotheWHT/BLKcontrolwireandtheSmartPodswilladvancetothenextprograminput.Eachtime12VDCismomentarilyappliedtotheWHT/BLKcontrolwiretheprogramnum-berwilladvance.Whenthelastavailableprogramnum-berisreachedthenextoperationwillselectthefirstavailableprogram,whichisOFF.
G. Ifprogramsassignedtotheotherslideswitchpositionsaretobechanged,movetheslideswitchtothedesiredpositionandrepeattheabovesteps.
-5-
Table 3-2
P1 Rear Oscillating Oscillating Oscillating Rotate Rotate Rotate FrontSwitches Flashing* Rear Intersection Front 90 120 175 Flashing(S2) FPM FPM FPM
P1A OFF ON OFF ON OFF ON OFF ONP1B OFF OFF ON ON OFF OFF ON ONP1C OFF OFF OFF OFF ON ON ON ON
Table 3-3
P2 Rotate Rotate Rotate Oscillating Oscillating Front Oscillating RearSwitches 90 120 175 Intersection Front Flashing Rear Flashing(S2) FPM* FPM FPM
P2A OFF ON OFF ON OFF ON OFF ONP2B OFF OFF ON ON OFF OFF ON ONP2C OFF OFF OFF OFF ON ON ON ON
Table 3-4
P3 Oscillating Oscillating Rotate Rotate Rotate Front Oscillating RearSwitches Intersection* Front 175 120 90 Flashing Rear Flashing(S1) FPM FPM FPM
P3C OFF OFF OFF OFF ON ON ON ONP3B OFF OFF ON ON OFF OFF ON ONP3A OFF ON OFF ON OFF ON OFF ON
*FactorySetting
H. Remove12VDCfromallcontrolwiresandtheRED10GApowerwire.Wait30secondsthenre-apply12VDCtoRED10GApowerwire.Checkforproperop-erationoflightbar.
EXAMPLE
Tochangefromthedefaultsto175FPMRotateinslideswitchpositionthree:
• DisconnecttheRED10GApowerwire.
• Usingtable3-4andfigure3-6,setDIPswitchP3BtoON.ThissetsP3to175FPMRotate.
• Apply12VDCtotheWHT/YELandWHT/BLKcontrolwires.
• ReconnecttheRED10GApowerwire.TherightupperLEDinPod4ison.
• Moveslideswitchtoposition3.All3LEDsinPod1comeonandtheSmartPodsarerotatingat90FPM.
• Remove12VDCfromtheWHT/BLKcontrolwire.Momentarilyre-apply12VDCtotheWHT/BLKcontrolwire.TheprograminputmovesfromP2toP3;theSmartPodsarenowrotatingat175FPM.
• Moveslideswitchtooff.
• Remove12VDCfromallcontrolwiresandtheRED10GApowerwire.Wait30secondsthenre-apply12VDCtoRED10GApowerwire.
• Checkforproperoperation.
IV. TESTING.
WARNING
This product contains high output LED de-vices. To prevent permanent eye damage, do not stare into the light beam at close range.
AfterInstallation,checktheentiresystemtobesurethelightsareflashingproperlyandalllightsystemfunctionsareoperatingproperly.
SAFETY MESSAGE TO OPERATORS
WARNING
People’s lives depend on your safe use of our products. Listed below are some im-portant safety instructions and precau-tions you should follow:
• Although your warning system is op-erating properly, it may not be com-pletely effective. People may not see or heed your warning signal. You must recognize this fact and continue driv-ing cautiously.
• Also, situations may occur which ob-struct your warning signal when natu-ral or manmade objects are between your vehicle and others, such as: rais-ing your hood or trunk lid. If these situations occur, be especially careful.
• This product contains high intensity LED devices. To prevent permanent eye damage, DO NOT stare into the light beam at close range.
• At the start of your shift, you should ensure that the light is securely at-tached and operating properly.
Failure to follow these safety precautions may result in property damage, serious injury, or death to you, to passengers, or to others.
RETAIN AND REFER TO THIS MESSAGE
-6-
V. SERVICE AND MAINTENANCE.
WARNING
Crazing (cracking) of lenses will cause re-duced effectiveness of the light. Do not use cleaning agent (which will cause crazing) such as strong detergents, solvents, or pe-troleum products. If crazing of lenses does occur, reliability of light for emergency signaling purposes may be reduced until lenses are replaced.
5-1. COLORED DOME INSERT OPTION INSTALLATION (SMART PODS ONLY).
WARNING
To provide proper warning colors to the front and/or rear if dome inserts are used, a clear dome must be used with the colored inserts.
A. RemoveandretainthetwoTorxheadscrewswhichsecurethedometothepod.
B. Carefullyremovethedomeandsetitaside.
C. Placethefrontorrearinsertinpositionandensurethatthelocatingnotchesareproperlypositionedonthelocatingribsasshowninfigure5-1.Ifapplicable,repeatwiththeotherinsert.
CAUTION
ExcessivetighteningoftheTorxheadscrewswilldamagethescrews.
D. Replacethedomeandsecurewiththeprevi-ouslyremovedTorxheadscrews.
-7-
5-2. SMART POD SERVICING. (See figure 5-2.)
A. RemoveandretainthetwoTorxheadscrewswhichsecurethedometothepod.Carefullyremovethedomeandsetitaside.
B. Togainaccesstothemotor,proceedasfol-lows:
1. Removeandretainthescrewswhichse-curethepodtothelightbarextrusion.
2. Removeandretainthescrewswhichse-curethemotorsupportassemblytothepod.
3. Disconnectthesix-pinmotorcableplugandthethree-pinoptoisolatorcable.
4. Carefullyliftthemotorsupportassem-blyfromthepod.
5. Afterservicingiscomplete,reassemblethepodbyperformingtheabovestepsinreverseorder.
5-3. PCB SERVICING.
CAUTION
Toavoiddamagetothelightbar,disconnectallpoweratthebatterybeforeproceeding.
A. Cover Removal.
Seefigure5-3.Removeandretainthefourscrewswhichsecurethecoveronthelightbar.Slidethecoverbackslightlyandcarefullylifttoremove.
290A5310-08
Figure 5-2.
290A5310-07
Figure 5-1.
B. Printed Circuit Board Removal.
Thelightbarcontainstwocircuitboards.Seefigure5-4.Toremoveacircuitboard,removeandretainthefastenerswhichsecurethecircuitboardtothelight-bar.
CAUTION
Unpredictableoperationmayresultifmotorcables,orlampdrivercables,aremixed.Beforeremovingcables,markthecablesforproperre-connectionwhenreassembling.
5-4. LED SERVICE.
A. Pod LED.
1. RemovedomeasdescribedpreviouslyinSection5-1.
2. Seefigure5-5.Noteormarkthescrewlocationtoensurereassemblyintheproperposition.Re-movethePhillipsscrewsretainingthereflectorassem-bly,slidetheassemblyfree,andunplugtheelectricalconnector.
CAUTION
Donotovertightenscrews.
3. Reassemblyisthereverse.DonotovertightenPhillipsscrews.Useduecautionwhenreplacing
screwsinpreviouslyinstalledreflectorassembliestore-engagetheexistingcutthreadintheplasticreflector.
B. Trioptic LED SignalMaster Removal and Installation.
1. RemovethecoverandSmartPod/SignalMasterboardasdescribedinSection5-3.A.
2. Disconnectcableconnectionandremovecableholddownclamp.
3. Seefigure5-6.Removethe4KepsNutssecuringtheSignalMastertothecover.RemovetheSignalMaster.
4. Installationisthereverse.
REMOVE AND REPLACE SCREW
BRACKET
REMOVE AND REPLACE SCREWS
290A5310-11
Figure 5-5.
290A5310-12B
KEPS NUT4PL
BOTTOM VIEW
Figure 5-6.
-8-
290A5310-10
SMART POD/SIGNALMASTERBOARD
MOTHERBOARD
Figure 5-4.
290A5310-09COVER SCREWS (2 TOP, 2 BACK)
Figure 5-3.
C. Trioptic SignalMaster LED Service.
Theunitmustnotbeopenedunderanycir-cumstance.Failuretoadheretothismayresultinmois-tureenteringintotheunitcausingprematurefailure.Pleasecontactthefactoryiftheunitisnotfunctioningproperly.
D. Standalone SignalMaster Connections.
Ifashortercableisdesired:
1. RemovethecoverandSmartPod/Sig-nalMasterboardasdescribedinparagraphs5-3.A.and5-3.B.
2. UnplugtheSignalMastercablefromtheboardandcutthecabletothedesiredlength,allowing4inchesforthecircuitboardconnection.Discardcutendandconnectors.
3. Seefigure5-7.Stripthecablejacketback4inches,thenstrip1/4”oftheinsulationfromthewiresshowninfigure5-7.
4. ConnectwiresthescrewheaderontheSmartPod/SignalMasterboardasshowninfigure5-7.
5. Testforproperoperation,trimextrawiresflushwithjacket,thenreassembleinreverseor-der.
5-5. MAINTENANCE.
A. Cleaning the Plastic Domes.
WARNING
Crazing (cracking) of domes will cause re-duced effectiveness of light system. Do not use cleaning agents (which will cause craz-ing) such as strong detergents, solvents, or petroleum products. If crazing of domes does occur, reliability of light for emergen-cy purposes may be reduced until domes are replaced.
Ordinarycleaningoftheplasticlensescanbeaccomplishedbyusingmildsoapandasoftrag.Shouldfinescratchesorahazeappearonalens,theycanbestberemovedwithaspecialtyplasticcleaner/polishsuchasPlexus®andasoftcloth.Alternatively,non-abrasive,highquality,one-step,automotivepastecleaner/waxmaybeused.
B. Smart Pods Lamp Replacement.
WARNING
A serious injury may result if lamp is touched when hot. Always allow lamp to cool before removing.
10 NO
NE
9 YE
L
8 GR
Y
7 VIO
6 NO
NE
5 BR
N
4 GR
N
3 OR
G
2 NO
NE
1 RE
D
290A5310-13
Figure 5-7.
1. RemoveandretainthetwoTorxheadscrewswhichsecurethedometothepod.
2. Carefullyremovethedomeandsetitaside.
CAUTION
Servicelifeoflampwillbeshortenedifglassportionistouched.Ifglasshasbeenhandled,cleancarefullywithagreasesolvent.
3. Toreplacethehalogenlamp,twisttoun-lockandthenpullthedefectivelampoutofthesocket.Installanew#795Xlampinthesocket(seefigure5-8).Refertoparagraph5-6fortheFederalSignalPartNum-ber.
4. Replacethedomeusingthepreviouslyremovedscrews.
-9-
Figure 5-8.
290A5310-15
-10-
5-6. SMART VECTOR SL REPLACEMENT PARTS LIST.
Description Part Number
Printed Circuit Boards
BarControllerPCB 2005245-12(Figure5-9)SmartPodController/SignalMasterPCB 2005325-12(Figure5-10)SmartPodController/SignalMasterPCB 2005325(Stand-aloneSML)OptoSensorPCB 2001079
Domes
Dome,Clear 8572001Dome,Red 8572001-01Dome,Amber 8572001-02Dome,Blue 8572001-03Dome,Green 8572001-04Dome,C.I.E.Blue 8572001-05
Smart Pod Assemblies
SmartPodAssy.,DriversSide(nodome) 8572101SmartPodAssy.,PassengerSide(nodome) 8572101-02
Smart Pod Components
Lamp(rotator)50WHal.Vert.Fil. 8107141MotorAndCableAssy. 175716
Description Part Number
Fuses
Fuse,2Amp.,PicoFuse 148151-08Fuse,2Amp.,AutomotiveBlade 148A142-10Fuse,5Amp.,AutomotiveBlade 148A142-03Fuse,15Amp.,AutomotiveBlade 148A142-06Fuse,20Amp.,AutomotiveBlade 148A142
LED Pod Components
PCBAssembly 2005272-1(tobereplacedby2005340-1)ReflectorAssembly,Amber(IncludesPCB) 8654167-12ReflectorAssembly,Blue(IncludesPCB) 8654167-13ReflectorAssembly,Red(IncludesPCB) 8654167-14ReflectorAssembly,White(IncludesPCB) 8654167-15LED,6Button,Amber 8625234-ALED,6Button,Blue 8625234-BLED,6Button,Red 8625234-RLED,6Button,White 8625234-WReflector,Polyparabolic 8654165LED,Trioptic3-pack,Amber(pod4R&L) 8572484-02LED,Trioptic3-pack,Blue(pod4R&L) 8572484-03LED,Trioptic3-pack,Red(pod4R&L) 8572484-04LED,Trioptic3-pack,White(pod4R&L) 8572484-05
-11-
J17
R30
Q2
+
R40
H3
H2
H4
F7
R55
+ +Q -
F6
J12+P - O - + N -
C28
F5D10
C33
F4
F3
C20
+
Q6
+ D4
+F2
U5
F1
C21
J10
R41
Q8
-J13
+M - L -
U8
+ K - + JJ14GG
HH EFF F HG NM -
U9
UPPER TAKEDOWNSALLEY- -
J15+ +
Q9
J16ORGWHT + SR -
R46
Q7
J11
R29
Q4
ALLEY
J9
A
+C10
D2
-U1
D C B
R6
R15
+
J1BB CC DD
J2+
JP4
MADE IN U.S.A.UNIVERSITY PARK, IL
FEDERAL SIGNAL CORP.
2005245A-
-
J3JJ
Q1
- - - + - KK +
1 2JP3
3
R7 R8
LL + MM- +
R9
NN- + -
GND
LF
H1
NSM
SM
JP5
U2
-OO
J4+ PP + QQ- + -
U3
-
J5+ - LR + -RF + RR +
R20 R22R19 R21
C49D21
RSB
R51 R52
J18
C46
SR+ - J19
C47
C42
D19D18
C43
D20
R53
SIGMAST INPUTSFSB
C48J20
U10
R47
C44
R48
C45
MAIN PROGJ21
R50
JP7
R49
R54 D22
C50
C24
R33R32
D17
D12
D14 D15
D11
D16
U6
D7
D5
D6 D8 D9
C38
R42
C34D13
R43
C39
C35
R36
C29
R37
C30
R31
R17 R18
C22
C16
C23
C17
R25
C11
R26
C12
R35R34
C37
R45
C41
R44
C40
C36
R39R38
C31 C32
1 U7
R24
D3C25
C19C18
C26
R28
C14
R27
C13
JP6
Y1
C15
C27
C9
R23
R16
PATTERN INPUTS
J7RIGHT
ALLEYSRIGHT
TAKEDOWNSLEFT
J6
Q3
LEFT
C5
R11
C6
R12
R1
C1
R2
C2
D1
R5
JP1
C8
R14
C7
R13
JP2
SM PROGRAM
R3 R4
C3 C4
J8
C52C51
U4
R10
290A5310-16
Figure 5-9.
290A5310-17
STANDALONE SML ONLY
Figure 5-10.
Copyright 2006 Federal Signal Corporation
