Carson SA-500-20 User manual

Carson Manufacturing Co., Inc.
5451 North Rural Street
Indianapolis, IN 46220
Phone: [phone] Fax: [phone]
www.carsonsirens.com
SA-500-20
28 VOLT
SIREN AMPLIFIER
INSTALLATION AND OPERATING
INSTRUCTIONS
Carson is a trademark of Carson Manufacturing Company, Inc.
Y
ELP
WAIL
STBY
RADIO
HORN PA
V
OLUME
MAN/PHSR
O
F
F
O
N
SA
-
500
RAD
OUTPUT
Sound Hazard - Sound level from siren speaker (>120dBA @ 10 feet) may cause hearing damage.
Do not operate siren without adequate hearing protection for you and anyone in immediate vicinity.
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)

Page 2 of 8 SA-500-20 28 Volt Installation and Operating Instructions
05/07/05 CP4930B
TABLE OF CONTENTS
GENERAL DESCRIPTION....................................................................................3
SPECIFICATIONS.................................................................................................3
INSTALLATION .....................................................................................................3
SAFETY PRECAUTIONS .................................................................................3
UNPACKING.....................................................................................................4
MOUNTING.......................................................................................................4
OPTION SWITCHES.........................................................................................4
ELECTRICAL CONNECTIONS.........................................................................5
OPERATION..........................................................................................................6
GENERAL .........................................................................................................6
SELECTOR SWITCH........................................................................................6
MAN/PHSR .......................................................................................................6
HORN................................................................................................................6
MICROPHONE..................................................................................................6
VOLUME CONTROLS ......................................................................................6
AUXILIARY INPUT............................................................................................6
CUTOUT ...........................................................................................................6
HORN RING CYCLER 2 (Optional) ..................................................................6
SERVICE ...............................................................................................................7
PROBLEMS ......................................................................................................7
PARTS ..............................................................................................................7
RETURN ...........................................................................................................8
LIMITED WARRANTY.......................................................................................8
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.
Carson Manufacturing Co., Inc. makes no warranty of any kind with regard to this manual, including, but not lim-
ited to, the implied warranties of merchantability and fitness for a particular purpose.
Carson Manufacturing 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.
INSTALLATION INFORMATION
MODEL: SA-500- ______________________ OPTIONS
SERIAL NO: __________________________ ______ Auxiliary Input Selection
PURCHASE DATE: _____________________ ______ Two-Tone Selected
DEALER: _____________________________ ______ Phaser Disabled
INSTALL DATE:________________________ ______Horn Disabled
INSTALLER: __________________________ ______ Yelp Override Selected
_____________________________________ ______ Short Manual Selected
_____________________________________ ______ HRC2 Selected
_________________________________________________ Cutout connection/polarity
_________________________________________________ Auxiliary connection/polarity
Model and serial number located on bottom of unit

SA-500-20 28 Volt Installation and Operating Instructions Page 3 of 8
CP4930B 05/07/05
GENERAL DESCRIPTION
The SA500 Siren Amplifier is a premium unit designed for single or dual 100W speaker use. The
primary operating modes are Yelp, Wail, Standby and Radio. A Noise Canceling PA Override and
push-button Horn Override are available in all modes except Radio. Another push-button is pro-
vided for push-on/push-off Phaser operation in the Yelp and Wail modes, and Manual siren con-
trol in the Standby mode. Auxiliary input is provided for connection to horn ring circuit or switch.
Latching siren cutout input is provided for connection to a door switch, etc. to stop siren tones
when exiting the vehicle. Radio and PA volume controls are provided on the front panel. The
front panel is backlit with LED's for night visibility. An internal 8-Position DIP switch allows selec-
tion of various options. This compact unit utilizes short circuit, high voltage, and reverse polarity
protection systems for maximum service life. Output indicator light on face for diagnostics.
SPECIFICATIONS
Input Voltage 18 - 32 VDC (negative ground)
Input Current 4 AMPS (@28 VDC - single 100W speaker)
8 AMPS (@28 VDC - dual 100W speakers)
Standby Current Less than 100 ma
Audio Frequency 200Hz - 10 kHz + 3db
Audio Distortion Less than 7% (@1 kHz - single 100W speaker)
Audio Output 40 watts (@28 VDC - single 100W speaker)
Audio Input 400 ohms + 10%
Output Power 105 WATTS RMS MAX. (30 VDC - single 100W speaker)
180 WATTS RMS MAX. (30 VDC - dual 100W speakers)
Siren Frequency 700Hz - 1500Hz (Two-Tone and Horn = 435 & 585Hz)
High Voltage Protection 32 - 36 VDC will cause siren output to cease, resume at normal
Short Circuit Current 50 AMPS (supply circuit must be capable of supplying this)
Operating Temp. -15° F to +140°F
Controls 4-position rotary mode switch (Yelp, Wail, Standby and Radio).
Momentary push-button Horn switch.
Momentary push-button Manual/Phaser toggle switch.
Front panel PA and Radio volume controls.
Auxiliary input connection programmable for positive or negative activation.
Cutout input connection programmable for positive or negative latching operation.
Internal 8-Position DIP switch option selector.
Connections (10-Pin Conn) (2) Positive, (2) Negative, (2) Speaker, (2) Radio, Cutout, Auxiliary
Size 6-1/8" Wide, 5-7/8" Deep, 2-1/8" High
Weight 4-1/2 LBS.
Tones/Cycle Rates Horn Wail Yelp Phaser Two-Tone
109 CPS 13 CPM 190 CPM 15 CPS 60 CPM
INSTALLATION
Proper installation of the unit is essential for years of safe, reliable operation. Please read all
instruction before installing the unit. Failure to follow these instructions can cause serious dam-
age to the unit or vehicle and may void warranties.
SAFETY PRECAUTIONS
For the safety of the installer, vehicle operator, passengers and the community please observe
the following safety precautions. Failure to follow all safety precautions and instructions may
result in property damage, injury or death.
Qualifications - The installer must have a firm knowledge of basic electricity, vehicle electrical
systems and emergency equipment.
Mounting - Mount the unit for easy access by the vehicle operator. DO NOT mount in air bag
deployment area. Assure clearances before drilling in vehicle. To prevent internal damage
mounting bolts must not enter case more than 1/4".
Sound Hazard - Sound level from siren speaker (>120dBA @ 10 feet) may cause hearing damage.
Do not operate siren without adequate hearing protection for you and anyone in immediate vicinity.
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)

Page 4 of 8 SA-500-20 28 Volt Installation and Operating Instructions
05/07/05 CP4930B
Wiring - Use wiring capable of handling the current required. Make sure all connections are tight.
Route wiring to prevent wear, overheating and interference with air bag deployment. Install and
check all wiring before connection to vehicle battery.
Testing - Test all siren functions after installation to assure proper operation. Test vehicle opera-
tion to assure no damage to vehicle.
Keep These Instructions - Keep these instructions in the vehicle or other safe place for future
reference. Advise the vehicle operator of the location.
UNPACKING
Inspect contents for shipping damage. If found alert carrier immediately. Contents should in-
clude unit with attached microphone, mounting bracket, microphone bracket with 2 screws, 2
mounting bolts, removable terminal block plug, and these instructions. Contact supplier immedi-
ately if any components are missing.
MOUNTING
The mounting bracket supplied can be installed above or below the unit. Choose a mounting
location convenient to the operator and away from any air bag deployment areas. Inspect behind
mounting area for clearance. Assure adequate ventilation to prevent overheating. Consider wire
routing and access to connections, as well as microphone bracket placement. Install mounting
bracket to vehicle using 1/4" hardware (not supplied).
If mounting in a rack or console, make sure that mounting bolts do not enter case more than 1/4".
OPTION SWITCHES
Various options can be selected by turning on
or off any of 8 DIP switches internally
mounted on the right side of the PC board.
Cover Removal - The cover is held in place
by a snap-fastener on the back of the unit.
Hold the unit with the front case flange on the
edge of a hard surface and press hard on the
back of the unit. The chassis will slide out the
front of the cover.
Cutout Input Polarity - The cutout input is
normally activated by connecting to positive.
To activate by connecting to negative turn off "CUT_P".
Auxiliary Input Polarity - The auxiliary input is normally activated by connecting to positive. To
activate by connecting to negative turn off "AUX_P".
Auxiliary Input Function - The auxiliary input normally activates the Horn function. To activate
the Man/Phsr function with the auxiliary input turn on "AUX_I".
Two-Tone - Two-Tone can replace Phaser by turning on "T-T".
Phaser Disable - The Phaser function can be completely disabled by turning on "P_I".
Note: when Phaser is disabled the Man/Phsr pushbutton will toggle between Wail and Yelp.
Horn Disable - The Horn function can be completely disabled by turning on "H_I".
Yelp Override - Causes the Man/Phsr function to toggle to Yelp with selector switch in Wail
mode. Turn on "YLP_O".
Short Manual - The Manual function can be set to immediately cut off when the Man/Phsr
pushbutton is released. Turn on "SM".
Horn Ring Cycler 2 (HRC2) - Turn on “T-T” and “P_I” to enable this feature. Also connect the
auxiliary input to the horn ring or other switch. While the siren is in standby, tap the horn ring to
bring the unit out of standby into Wail tone. Repeatedly tapping the horn ring will cycle through
Wail, Yelp, and Phaser tones. Tapping the horn ring twice quickly will stop the siren tones and
return the unit to standby. Pressing and holding the horn ring will produce Horn tone until re-
leased. Then the siren will return to its previous siren tone or standby.
NOTE: Earlier models with S/N lower than 04190000 have a different version of HRC. In this
case the siren tones cycle through Standby, Wail, Yelp, and Phaser. The tone is stopped by cy-
cling to Standby.
OPTION SWITCHES
FUSE
SIDE VIEW
COVER REMOVED

SA-500-20 28 Volt Installation and Operating Instructions Page 5 of 8
CP4930B 05/07/05
ELECTRICAL CONNECTIONS
Electrical connections to the unit are made
using a removable terminal block plug
located on the back. A label on the unit
identifies the terminal function. You
should install the plug on the unit before
wiring. If the unit needs service the plug
can be easily removed without unwiring.
The power supply of the unit must be ca-
pable of delivering peak currents up to 50
amps for adequate short circuit protection
and reliable operation. The preferred
source is directly at the vehicle battery.
The unit is internally fused.
Attach leads by stripping 3/8", inserting
into plug and clamp by tightening screw.
Make sure the screw is tight and the wire
can't be pulled out. Failure to adequately
tighten the screw can result in im-
proper operation or burning the con-
nector and wire.
Wire Size and Termination - The diagram shows the minimum wire size used for each connec-
tion, along with recommended lead color. If the wire is longer than 10 ft. use the next larger wire
size. Use only high quality crimp connectors for installation on the vehicle.
Auxiliary Input Connection -
The Auxiliary Input allows acti-
vation by an external source of
either the Horn or Man/Phsr
function. The adjacent diagram
shows three connection exam-
ples. See OPTION SWITCHES
section for programming details.
NOTE: Permanent disconnec-
tion of the vehicle horn is NOT
recommended.
Cutout Input Connection - The Cutout Input turns
off any siren tone output when activated, and remains
off until a control is activated or changed. The adja-
cent diagram shows two connection examples. See
OPTION SWITCHES section for programming de-
tails.
CONNECTIONS AT REAR OF UNIT WITH
10-PIN TERMINAL BLOCK PLUG (CP4688-10)
(2) #18 AWG BRN
(#16 - 2 SPKR)
2 - SPKR - Connect for
same phase (+ to +)
SPKR → SPKR →
POS → POS →
RAD → RAD →
AUX →
CUT →
NEG → NEG →
••••••••••
#22 AWG WHT (See below)
#22 AWG GRN (See below)
(2) #22 AWG BLU
Connect to output
jack, terminals or
speaker of radio
#14 AWG RED
Use second lead
for 2 - SPKR
#14 AWG BLK
Use second lead
for 2 - SPKR
RADIO
+
BAT
-
+VDC Switching examples
HORN
RING
SWITCH
+VDC
AUX
SPLICE
HORN
RING
SWITCH
+VDC
AUX
Added
SPDT
Switch
HORN
HORN
-VDC
switching
example
Must set AUX_P
option switch
MOMENTARY
FOOT
SWITCH
AUX
-VDC
switching
example
Must set CUT_P
option switch
ADDED
DOOR
SWITCH
CUT
+VDC Switching
example
DOOR
SWITCH
+VDC
CUT
SPLICE
DOME
LIGHT

Page 6 of 8 SA-500-20 28 Volt Installation and Operating Instructions
05/07/05 CP4930B
OPERATION
GENERAL
This unit is designed for easy operation under the stress associated with high-speed pursuit.
Most siren functions are accessible with one simple motion without repetitive activation of
switches or automatic timed switching that can interfere with desired operation.
SELECTOR SWITCH
The rotary selector switch controls the primary operating
mode of the siren.
Yelp - A rapidly changing tone used in congested areas.
Wail - A slower changing tone used on highways.
Stby - A silent mode that allows Manual, Horn and Public
Address operation.
Radio - Also known as Radio Repeat, this mode amplifies
a radio speaker input for re-broadcast outside the vehicle.
No siren tones or PA operation are available in this mode.
MAN/PHSR
This momentary push-button switch provides a very rapid changing tone (Phaser) when the selec-
tor switch is in the Yelp or Wail positions. This tone is used at intersections and very highly con-
gested areas. Pressing the button once changes to the Phaser tone and pressing again changes
the tone back to Yelp or Wail.
With the selector switch in the Stby position this switch
provides Manual siren tone control, rising when pressed
and falling when released. This is used to momentarily
alert motorists or in low noise areas.
Phaser may be replaced by Two-Tone or disabled.
See OPTION SWITCHES section.
HORN
This momentary push-button switch provides a simulated air-horn tone while pressed. This can
be used to supplement the normal vehicle horn and is useful at intersections or in low noise areas.
This tone overrides other siren tones. Horn may be disabled. See OPTION SWITCHES section.
MICROPHONE
The attached noise-canceling microphone is used for public address operation and overrides any
siren tone when the button on the side (PTT) is pressed.
VOLUME CONTROLS
Controls are provided for radio repeat volume and public address
volume. These should be set when the vehicle is parked. Set
the RAD volume with the selector switch in the Radio position
and the radio volume set to desired level. Set the PA volume to
the maximum level with no feedback (squeal).
AUXILIARY INPUT
During installation an auxiliary input may be connected to the horn ring or other switching device.
It provides the same operation as pressing the Horn button or optionally the Man/Phsr button.
CUTOUT
During installation, a cutout input may be connected to a door switch. It turns off any siren tone
when the door is opened. The siren tone will continue to be cut off even when the door is closed.
Changing any switch or input will restore normal function.
HORN RING CYCLER 2 (Optional)
Available while selector switch is in standby, repeatedly tapping the horn ring or other switch will
cycle through Wail, Yelp, and Phaser tones. Tapping the horn ring twice quckly will stop siren
tones. Holding the horn ring produces horn. See OPTION SWITCHES section for further details.
MAN/PHSR HORN
VOLUME
RAD PA
H L H L
YELP
WAIL
STBY
RADIO
Sound Hazard - Sound level from siren speaker (>120dBA @ 10 feet) may cause hearing damage.
Do not operate siren without adequate hearing protection for you and anyone in immediate vicinity.
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)

SA-500-20 28 Volt Installation and Operating Instructions Page 7 of 8
CP4930B 05/07/05
SERVICE
This unit is designed to provide years of reliable service under even the worst conditions. Many
times there may appear to be a problem with the unit when the true problem is in the speaker(s)
or improper installation. The following chart shows typical symptoms and possible causes.
A blown internal fuse doesn't necessarily mean that the unit is bad. If a speaker or speaker lead
is shorted the internal fuse will blow before the unit is damaged. Disconnect the SPKR leads and
replace the fuse. If the OUTPUT light comes on (dim lighting to see) with power on and Yelp
selected it is OK. Check the speaker(s) or leads for possible shorting.
PROBLEMS
PARTS
The following parts are available from Carson Manufacturing Company, Inc.:
Symptom Possible Cause Check
No power or siren
output
Power switch not turned on
Bad speaker(s)
Connector loose
Internal fuse blown
Loose connection at power source
Does backlighting come on?
Do you hear a "pop" when turned on?
Is the OUTPUT light on front panel coming on in Yelp?
Is an external fuse or circuit breaker used?
Are the negative leads connected to a good ground?
No siren tone -
PA works
High Voltage Protection
Mic button stuck
Cutout activated
Cutout Polarity Option set wrong
Input voltage must be less than highest rated voltage.
Does mic button release properly?
Does the siren work when Cutout input is disconnected?
Is the CUT_P option properly configured?
No PA PA volume not set properly
Selector in Radio position
Have you tried turning the PA volume control?
PA is not available in the Radio position
Distorted siren
sound
Speaker assembly loose
Intermittent Aux Input connection
Low vehicle voltage
Is the speaker bell or tip loose?
Is the Auxiliary Input used and wired properly?
Input voltage must be greater than lowest rated voltage.
Intermittent siren
tone
High Voltage Protection
Connector loose
Bad power connection
Mic button activation
Circuit breaker in supply connection
Is the vehicle voltage regulator working properly?
Is the connector tight on the back of the unit?
Is there a loose connection on a power lead?
Is something lying on the microphone?
Is a circuit breaker used with at least a 50A rating?
Horn function
or
Manual or Phaser
stuck on
Horn switch stuck
Man/Phsr switch stuck
Aux Input improperly connected
Aux Input Polarity Option set wrong
Does the horn switch return fully when released?
Does the Man/Phsr switch return fully when released?
Is the Aux Input used and wired properly?
Is the AUX_P option properly configured?
No Radio Unit not connected to radio
Radio volume too low
Is the radio connected properly to the unit?
Can you here the radio in the vehicle?
Have you tried turning the RAD volume control?
Wrong siren tone Two-Tone option installed
Aux Input set to wrong function
Yelp Override option installed
Is the T-T option selected?
Is the AUX_I option configured properly?
Is the YLP_O option selected?
Phaser not work-
ing
Phaser disabled Is the P_I option selected?
Horn not working Horn disabled Is the H_I option selected?
Part Description
CP3966 Bolt, mounting, 1/4-20 X 3/8” (2 required)
CP3571 Bracket, mounting
CP4688-10 Connector, 10-pin Terminal Block Plug
CP4680-1 Cover (not including chassis)
ATO/ATC 10A Fuse, 10 Amp Automotive
CP4852 Knob, selector switch
CP4750 Microphone, Noise Canceling w/Connector
CP3633 Microphone Bracket with mounting Screws
SR-15-1 Microphone Strain Relief
CP4119 Transistor, output (2 required) (Industry standard TIP36C, Not Texas Instruments)
ED1558 Hardware Kit (Connector, bolts, microphone bracket with screws)
CP4930 Instruction Manual

Page 8 of 8 SA-500-20 28 Volt Installation and Operating Instructions
05/07/05 CP4930B
RETURN
If you have any questions concerning this or any other Carson product,
please contact our Technical Service Department at [phone].
Many issues can be handled over the phone. We can also be reached via
e-mail at [e-mail]
If a product must be returned for any reason, please contact our Technical
Service Department to obtain a Returned Merchandise Authorization num-
ber (RMA#) before you ship the product to Carson. Please write the RMA#
clearly on the package near the mailing label. Be sure to provide a return
address, contact and phone number, along with a brief description of the
problem.
LIMITED WARRANTY
Carson Manufacturing Company, Inc. warrants this new product to be free from defects
in material and workmanship, under normal use and service, for a period of five (5)
years from the date of delivery to the first user-purchaser.
During this warranty period the obligation of Carson Manufacturing is limited to repairing
or replacing, as Carson Manufacturing may elect, any part or parts of such product
which after examination by Carson Manufacturing is determined to be defective in mate-
rial and/or workmanship.
This warranty does not cover labor charges for removal or re-installation of the product.
Fuses and lamps are not covered under this warranty.
This warranty does not extend to any unit that has been subjected to abuse, misuse,
improper installation or which has not been adequately maintained, nor to units which
have problems related to service or modification at any facility other than the manufac-
turer.
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL CARSON MANU-
FACTURING COMPANY, INC. BE LIABLE FOR ANY LOSS OF PROFITS OR ANY
INDIRECT OR CONSEQUENTIAL DAMAGES ARISING OUT OF ANY SUCH DEFECT
IN MATERIALS OR WORKMANSHIP.