Ecco Axios User manual

1ENGLISH

2
CONFIGURE. BUILD. DEPLOY.
Axios™ is the world’s rst modular LED lightbar system. Designed and engineered by ECCO for quick conguration, easy
upgrading, and simple operation. Each Axios lightbar is supplied with a plug and play in-cab controller providing ngertip
control of up to nine available functions including ash pattern selection, hi/lo intensity, and cruise mode. The aluminum
smart chassis features an integrated DropLock™ power rail and module system that makes installing, reconguring, or
upgrading LED modules quick and simple. Choose from 360° beacons, directional warning, worklamps, alley lights, stop-
tail-indicators, center illumination and an external Safety Director to create a custom lighting solution for your specic
application. When congured properly, the Axios lightbar meets SAE Class 1, California Title 13, and ECE R65 as well as ECE
R6, R7, and R10.
Axios is available in ve lengths, features 12-24V operation, and uses CAN bus technology for fast, easy installation. Tilt
adjustable mounting feet allow for varying rooine contours and a range of accessory mounting kits are available for
specic vehicle installations.

3ENGLISHENGLISH
INSTALLATION & OPERATION INSTRUCTIONS
Components & Specication ......................................................................................................................... 4
Unpacking & Pre-Installation ..................................................................................................................... 4
Specications.............................................................................................................................................. 4
Certications .............................................................................................................................................. 4
Mounting ........................................................................................................................................................ 6
Permanent Mounting ................................................................................................................................ 6
Gutter Mounting ........................................................................................................................................ 8
Roof Mounting Kits.................................................................................................................................... 8
Wiring Instructions ........................................................................................................................................ 10
Programming & Operating .......................................................................................................................... 12
Primary Warning & General Function...................................................................................................... 12
Safety Director Functions.......................................................................................................................... 13
Scene Illumination Functions.................................................................................................................... 13
Keypad Controller Mounting ................................................................................................................... 14
Flash Pattern Chart.................................................................................................................................... 15
Assembly & Conguration ............................................................................................................................ 16
Smart Chassis ............................................................................................................................................. 16
Removing & Installing the Lens................................................................................................................ 18
Installing DropLock™ LED Modules......................................................................................................... 20
Directional Modules (EZ1401X) .......................................................................................................... 20
Beacon Modules (EZ1402X) ................................................................................................................ 22
Worklamp Modules (EZ1403WL) ........................................................................................................ 24
Alley Light Modules (EZ1403AL) ........................................................................................................ 26
Stop-Tail-Indicator Modules (EZ1404) ................................................................................................ 28
Safety Director™ (EZ1414) .................................................................................................................. 30
Center Illumination (EZ1411).............................................................................................................. 32
Troubleshooting ............................................................................................................................................ 34
Warranty & Limitation of Liability ............................................................................................................... 35
Replacement Parts & Accessories ................................................................................................................. 36
Register Your Axios™ Modular LED Lightbar .............................................................................................. 36
INSTALLATION &
OPERATION
INSTRUCTIONS
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4
Specifications
Length .................................39”/1m, 48”/1.2m, 54”/1.37m,
.............................................60”/1.5m, 72”/1.8m
Height .................................3”/76mm (5”/127mm w/ mounting feet)
Width ..................................10.5”/267mm
Voltage................................12-24 VDC
Operating Temperature .....-30ºC to +50ºC (-22ºF to +122ºF)
Current Draw ............................LED Directional = 0.5A Avg. @ 12 VDC
..........................................................LED Beacon = 0.5A Avg. @ 12 VDC
..........................................................LED STI = 0.3A Avg. @ 12 VDC
..........................................................LED Alley Light (pair) = 0.9A Avg. @ 12 VDC
..........................................................LED Worklamp (pair) = 0.9A Avg. @ 12 VDC
..........................................................LED Safety Director = 2.5A Avg. @ 12 VDC
..........................................................Center Illumination = 0.7 Avg. @12 VDC
..........................................................Max Standby = 0.45A @ 24 VDC / 0.35A @ 12 VDC
Flash Patterns .....................29 (see chart on page 15)
Certifications
• SAE J845 Class I: Beacons & Directionals
• J595 Class 1: Safety Director
• ECE Regulation 65: Beacons & Directionals
• California Title 13: Directionals
• ECE Regulation R6 & R7: Stop-Tail-Indicators
• ECE Regulation 10
Note: Compliance with SAE Class I, California Title 13 and ECE
Regulation 65 is dependent on both the specic conguration of
warning modules within the lightbar (see pages 21 & 23) and the
selected ash pattern (see page 15).
Unpacking & Pre-Installation
All Axios lightbars include an aluminum chassis with solid-state
electronics, a three or ve-piece polycarbonate lens assembly
(depending on chassis length), a keypad controller and an
electrical junction box. The specic type and conguration
of the lighting modules of the lightbar is dependent on the
options selected at the time of purchase.
Carefully remove the lightbar and place it on a at surface.
Examine the unit for transit damage and locate all parts. If
damage is found or parts are missing, contact your Axios
distributor or ECCO. Do not use damaged or broken parts.
Ensure the lightbar voltage is compatible with the planned
installation.
Examples
COMPONENTS & SPECIFICATION
72” lightbar & components
48” lightbar & components

5ENGLISH
Read all instructions before installing and using. Installer: This manual must be delivered to the end user.
This manual assumes installation by a suitably qualied Automotive Technician.
Failure to install or use this product according to manufacturer’s recommendations may result in property
damage, serious bodily/personal injury, and/or death to you and those you are seeking to protect!
Do not install and/or operate this safety product unless you have read and understand the
safety information contained in this manual.
IMPORTANT WARNINGS
1 Proper installation combined with
operator training in the use, care
and maintenance of emergency
warning devices are essential to
ensure the safety of emergency
personnel and the public.
2 Emergency warning devices
often require high electrical
voltages and/or currents. Exercise
caution when working with live
electrical connections.
3 This product must be properly
grounded. Inadequate grounding
and/or shorting of electrical
connections can cause high current
arcing, which can cause personal
injury and/or severe vehicle damage,
including re.
4 Proper placement and
installation is vital to the
performance of this warning
device. Install this product so that
output performance of the system
is maximized and the controls are
placed within convenient reach
of the operator so that s/he can
operate the system without losing
eye contact with the roadway.
5 It is the responsibility of the
vehicle operator to ensure daily
that all features of this product
work correctly. In use, the vehicle
operator should ensure the
projection of the warning signal is
not blocked by vehicle components
(i.e., open trunks or compartment
doors), people, vehicles or other
obstructions.
6 The use of this or any other
warning device does not ensure all
drivers can or will observe or react
to an emergency warning signal.
Never take the right-of-way for
granted. It is your responsibility
to be sure you can proceed safely
before entering an intersection,
driving against trafc, responding
at a high rate of speed, or walking
around trafc lanes.
7 This equipment is intended
for use by authorized personnel
only. The user is responsible for
understanding and obeying all laws
regarding emergency warning
devices. Therefore, the user should
check all applicable city, state, and
federal laws and regulations. The
manufacturer assumes no liability
for any loss resulting from the use of
this warning device.
8 This product may contain high
intensity LEDs staring directly
into these lights could result in
temporary and/or permanent vision
impairment.
COMPONENTS &
SPECIFICATION

6
Before proceeding with installation, plan all wiring and cable routing. Select the mounting location for the lightbar on a at,
smooth surface and center the unit across the width of the vehicle. The mounting location for the lightbar should be chosen
such that the lightbar is level and visibility to approaching trafc is optimized. Mounting should be such that there is no less
than ½”/12.7mm clearance between the roof and the lightbar at any point. Both the height and angle of the mounting feet
can be adjusted slightly if necessary using the bolts indicated opposite.
MOUNTING
Permanent Mounting
Determine the location of the lightbar, and the best
route for the wiring.
Determine the position of the mounting feet and drill the
5/16”/7.8mm - 11/32”/8.7mm diameter mounting holes
accordingly, if needed. The spacing of the mounting
feet from left to right is adjustable. It is suggested that
the positioning of the feet be symmetrical and near the
curved edges of the roof where the roof is strongest.
Ideally, the outermost holes on the feet should be used
for installation. The inner holes on the feet match the
hole locations for ECCO 10 and 15 Series lightbars and
can be used when one of these lightbars has been
CAUTION
When drilling into any vehicle surface, make sure that the area is free from any electrical wires, fuel lines, vehicle upholstery, vehicle
support members, etc. that could be damaged.
previously installed.
Mount the lightbar, with the bolts going through the
holes drilled in step 2 (refer to diagram), routing the
wire as planned in step 1. See the Wiring section (on
page 10) of this manual for further wiring instructions.
Install appropriate washers and nuts and secure the unit.
The use of sealing compound is recommended.
Note: The cable exits the lightbar from the center of the
chassis, and can be pressed into the channels on the underside
of the chassis to route it toward the left or right of the vehicle.
1
2
3

7ENGLISH
VEHICLE ROOF
LIGHTBAR
LOAD WASHER
5/16” NYLOCK NUT
5/16” COACH BOLT
HEIGHT/ANGLE ADJUSTMENT
7.86”/200mm
5.31”/134mm
MOUNTING
Permanent Mounting
KEYPAD
CONTROLLER
MOUNTING
Refer to page 14

8
Gutter Mounting
Insert the cage nut as shown opposite. It will t snugly
underneath the mounting foot. Do not install it on the
outside face.
Adjust the spacing of the mounting feet before securely
tightening the nuts.
Hand thread the M6 screw through the star washer and
mounting strap into the cage nut. Be careful not to cross
thread the bolt, and leave loose until later steps.
IMPORTANT
Mounting straps are specic to the vehicle model. Please make sure the straps are suitable for the vehicle before installation.
Open the doors of the vehicle and position lightbar. Use
the strap as a template to drill Ø1/8”/3.17mm holes in
the roof gutter. It may be necessary to pull back the
door sealing gasket or trim. Apply silicone or sealant
around the hole, behind the strap. Secure the straps
with the provided #10 stainless steel sheet metal screws
with washers as shown. Screws should be tightened to
around 5-10 in-lb.
Tighten the M6 screw evenly so that the bar is even and
centered. Reinstall any removed trim and/or weather-
stripping and close doors to check secure t of the
Please call ECCO Customer Service or your local Axios Distributor for more options.
Roof Mounting Kits
Ford, Truck, 1/2T, 2004-09 ........................................ A1010RMK
Ford, Truck, 3/4T-1T, 1999-2009 ............................... A1012RMK
Ford, Crown Vic, 1998-2013 ..................................... A1013RMK
Ford, Truck, 1/2T, Crew Cab, 1997 ........................... A1014RMK
Ford, Truck, 1/2T, 2010-2015 .................................... A1025RMK
Ford, Super Duty Truck, 2010-2015 ......................... A1026RMK
Vehicle Part #
GM, Truck, 1/2T-1T, 1999-2009 ................................. A1011RMK
GM, Truck, 1/2T-1T, 2010-2014 ................................. A1027RMK
GM, Truck, 1/2T-1T, 2015 .......................................... A1025RMK
Dodge, Charger, 2007-2010 ..................................... A1029RMK
Dodge, Charger, 2011-2015 ..................................... A1031RMK
Dodge, Truck, 1/2T-1T, 2002-2013 ............................ A1011RMK
Headache Rack Mounting Brackets ........................ A1401RMK
Vehicle Part #
1
2
3
4
5

9ENGLISH
SHEET METAL SCREWS
MOUNTING STRAP
#10 STAR WASHERS
M6 SCREW
M6 STAR WASHER
VEHICLE ROOF
Ø1/8” /3.17mm HOLES
LIGHTBAR
M6 CAGE NUT
MOUNTING FOOT
MOUNTING
Gutter Mounting
KEYPAD
CONTROLLER
MOUNTING
Refer to page 14

10
Before attempting to connect the lightbar wiring harness, refer to the
wiring diagram illustrated opposite which describes the function for each
wire. After the lightbar has been mounted, route the power cable to the
junction box (the junction box must be mounted in an interior location).
Route the power red wire from the junction box to a fused, ignition-
switched power point. Connect the black power wire to a solid ground
connection on the vehicle (ideally, directly to the battery negative terminal).
Use a fuse according to the wiring diagram.
To Use the Keypad Controller
Route the control cable from the junction box to the chosen controller location and
connect to the controller.
To Use Switches
Route and connect the wires of the optional wire control harness from the junction
box to the battery positive via switches (not supplied). See the wiring diagram wire
color/function legend. Some wires may be unused dependent on specic lightbar
conguration.
Wiring the Stop-Tail-Indicator Function
Connect the Tail/Stop/Right/Left wires from the STI/Aux/Sync wire harness from the
junction box to the corresponding wires of the vehicle electrical system.
Wiring the Auxiliary Switch Output
Connect the Brown (Aux Out) wire from the STI/Aux/Sync wire harness from the junction
box to the positive coil of a 12 VDC relay. Connect the negative side of the coil to ground.
Run a properly-fused load wire to one contact of the relay (COMMON). Run a second
load wire from the other relay contact (Normally Open) to the Auxiliary device to be
powered. Run a ground wire from the other side of the Auxiliary device to ground.
Use cable ties and grommets to secure and protect all cables and wires.
WIRING INSTRUCTIONS This unit is a safety device and it must be connected
to its own separate, fused power point to assure
its continued operation should any other electrical
accessory fail. Do not wire in parallel with any other
accessory.
1 Larger wires and tight connections will provide longer
service life for components. For high current wires it is
highly recommended that terminal blocks or soldered
connections be used with shrink tubing to protect the
connections. Do not use insulation displacement connectors
(e.g., 3M Scotchlock type connectors).
2 Route wiring using grommets and sealant when passing
through compartment walls. Minimize the number of
splices to reduce voltage drop. High ambient temperatures
(e.g., under-hood) will signicantly reduce the current
carrying capacity of wires, fuses, and circuit breakers. All
wiring should conform to the minimum wire size and other
recommendations of the manufacturer and be protected
from moving parts and hot surfaces. Looms, grommets,
cable ties, and similar installation hardware should be used
to anchor and protect all wiring.
3 Fuses or circuit breakers should be located as close to
the power takeoff points as possible and properly sized to
protect the wiring and devices.
4 Particular attention should be paid to the location and
method of making electrical connections and splices to
protect these points from corrosion and loss of conductivity.
5 Ground termination should only be made to substantial
chassis components, preferably directly to the vehicle
battery.
6 Circuit breakers are very sensitive to high temperatures
and will “false trip” when mounted in hot environments or
operated close to their capacity.
Disconnect the battery before wiring up the
lightbar, to prevent accidental shorting, arcing
and/or electrical shock.
IMPORTANT
WARNINGS

11ENGLISH
WIRING
INSTRUCTIONS
AXIOS LIGHTBAR
Junction Box
Black
Red
Blue
Yellow
BLK
RED
20A
Ignition
Switch
Axios Keypad
Pattern 1 (Black)
Pattern 2 (Yellow)
Alley Left (Red)
Alley Right (Green)
Rear Worklamps (Blue)
Pattern Sel (Violet)
Batt +
2A Mom
Cruise (Orange)
Front Worklamps (Brown)
Optional Wire Control Harness*
(Brown) Aux Out (connect to a relay coil)
(Yellow) Right
(Green) Tail
(Black) Left
(Blue) Stop
(White) Sync
STI/Aux/Sync Harness
NOTE
*If using the keypad controller to operate the lightbar, disconnect the optional wire control harness
from the junction box.

12
USING THE KEYPAD CONTROLLER TO PROGRAM & OPERATE AXIOS™
Keypad Controller
EZ1405
The controller provides convenient control of the Lightbar’s flash patterns and auxiliary functions and features soft touch
buttons and LED function indicator lights. See page 14 for mounting instructions.
Power Button
Press to cycle through three
programmable ash pattern
presets. Hold button down to
shut down all functions. Press
again to resume as before. Preset 1 Preset 2 Preset 3
Off
Cruise Button
Press to illuminate all
beacon/directional
modules (steady burn).
Day/Night Mode Button
For use if parking lights are not
connected to junction box. When
active, provides backlight to keypad
and lowers intensity of the beacon/
directional modules in the lightbar.
Auxiliary Output Button
For use with the auxiliary output
from the junction box to a relay
(customer supplied), to control
any auxiliary device via the
junction box controlled relay.
Flash Pattern Select Button
Press to cycle through beacon/directional ash patterns. The
keypad will remember the pattern used and store it to the
active preset. Double tap the button to begin cycling. The 4
corner leds will mimic the bar, to give pattern feedback.
Corner LED
Primary Warning & General Function

13ENGLISH
PROGRAMMING
& OPERATING
Keypad Controller
Safety Director LEDs
Safety Director On/Off Button
(if equipped)
Will resume pattern selected.
Safety Director Pattern
Select Button
Press to cycle through Safety Director patterns.
The 6 LED windows will mimic the pattern for
realtime feedback.
Forward
Worklamp
Button
Will turn on forward
facing worklamps
when properly
congured.
Rear
Worklamp
Button
Will turn on rear
facing worklamps
when properly
congured.
Alley
Left
Button
Will turn on left
alley lights when
properly congured.
Alley
Right
Button
Will turn on right
alley lights when
properly congured.
Safety Director™Functions
Scene Illumination Functions

14
Keypad Controller Mounting
The Keypad is supplied with three
mounting options: a bracket, VHB tape
and hook and loop patch. The rear of
the Keypad is designed to allow for the
cable exit to be routed five different
ways to maximize installation locations.
Mount the controller in a location within
convenient reach of the operator so that
s/he can operate the system without
losing eye contact with the roadway.
Flash/Rotate Pattern Mode
Pressing both alley light buttons
simultaneously for two seconds will
switch the beacon mode between
“flash” and “rotate” modes.
ECE Regulation 65 Only Mode
To enable only ECE Regulation 65 flash
patterns, press and hold the front and
rear worklamp buttons simultaneously
for 5 seconds. The keypad flash pattern
indicators will flash twice. Repeat the
procedure to re-enable all flash patterns.
BRACKET
HOOK AND LOOP
PATCH
VHB TAPE

15ENGLISH
PROGRAMMING
& OPERATING
Keypad Controller
Mounting
& Flash Patterns
FLASH PATTERN CHART
# Description FPM SAE T13 R65
1 Steady Burn -
2 CA Title 13 Double 75
3 CA Title 13 Slow Quad 65
4 CA Title 13 Slow Double 65
5 CA Title 13 Quint 75
6 Pulse8 75
7 R65 Single 120
8 R65 Double 120
9 R65 Triple 120
10 R65 Quad 120
11 R65 Burst 120
12 R65 Single Side-to-Side 120
13 R65 Double Side-to-Side 120
14 R65 Triple Side-to-Side 120
15 R65 Quad Side-to-side 120
16 R65 Burst Side-to-Side 120
17 Quad Alternate Side-to-Side 75
18 Quad Cross Alternate 75
19 Double Alternate Side-to-Side 75
20 Double Cross Alternate 75
21 Quint Alternate Side-to-Side 75
22 Quint Cross Alternate 75
23 Quad Alternate Side-to-Side Front 75
24 Quad Alternate Side-to-Side Rear 75
25 Double Alternate Side-to-Side Front 75
26 Double Alternate Side-to-Side Rear 75
27 Quint Alternate Side-to-Side Front 75
28 Quint Alternate Side-to-Side Rear 75
29 Cycle All (2,3,5,6,13,15,16) -
# Description FPM SAE T13 R65
1 R65 Rotate 120
ROTATE MODE (BEACONS ONLY)
# Description
1 Left
2 Left Solid
3 Right
4 Right Solid
5 Center Out
6 Center Out Solid
7 Wig Wag
8 Alternating
9 Alternating Quad Flash
FLASH MODE (SAFETY DIRECTORS ONLY)
SAE
NOTES: • EZ1402A amber beacon modules do not meet California Title 13 • EZ1402B blue beacon modules do not meet ECE Regulation 65 • ECE Regulation 65 and California Title 13 do not apply to clear (white)
modules. • SAE, ECE Regulation 65, and California Title 13 do not apply to green modules. • All R65 flash patterns meet ECE Regulation 65 Class II, Beacon modules meet ECE Regulation 65 Class I only. • All SAE flash
patterns meet Class I in day mode and Class II in night mode. • Flash patterns #12 - #22 meet SAE Class 1S 180º • Flash patterns #23 - #29 meet SAE Class 1S 90º

16
ASSEMBLY & CONFIGURATION
Axios is designed to enable quick and easy customization
without the need for tools using any of the available Droplock™
LED modules while the Safety Director module requires only
basic hand tools for installation. Each lightbar is sold pre-
assembled with a minimum of two lighting modules installed.
If reconguration of the existing modules in the lightbar, or
the installation of additional modules is required this can be
achieved in just a few minutes by following the instructions
for each module outlined in this section. Additional modules
can be obtained from Axios Distributors.
Before attempting to recongure or upgrade the lightbar,
ensure power is disconnected and familiarize yourself with
the features and components of the chassis.
Identify the central control board. The control board
distributes power and control signals to the Droplock™
power rails and Safety Director. The logo illuminates
when power is applied to the lightbar.
Identify the Safety Director data port on the central
control board, this is used to supply power and control
signals to the Safety Director.
Identify the Safety Director grommet blank. This notch
in the lip of the chassis is used to route the Safety
Director cable into the lightbar. When a Safety Director
is installed, the blank grommet is discarded and replaced
with a cable grommet supplied with the Safety Director.
Identify the front and rear of the lightbar. To operate
properly, some LED modules must be positioned in a
specic orientation. The rear of the lightbar is easily
identied as the Safety Director data port on the central
control board faces the rear of the lightbar.
Identify the three DropLockTM power rails. The power
rails supply power and control signals to the Droplock™
lighting modules.
1
2
3
4
5
SAFETY
DIRECTOR
4FRONT
7
85
a
b
a

17ENGLISH
ASSEMBLY &
CONFIGURATION
Smart Chassis
The front and rear power rails are used for beacon and
directional warning modules as well as the stop-tail-
indicator and center illumination modules.
The center power rail is used for front/rear worklamps,
and alley lights.
Identify the module positioning guides. These markers are
intended to assist with the symmetrical placement of modules.
Identify the stop-tail-indicator (STI) data port. The STI modules
must be positioned/connected with this port.
Identify the locking lens latch. These latches secure the lens
to the chassis.
a
b
6
7
8
SAFETY
DIRECTOR
1
2
3
5
6
7
8
a
a
b
WARNING
Ensure total average
current draw for any
lightbar configuration is
less than 20A. Reference
average module current
draws on page 4.

18
Removing the Lens
Repeat steps 1-4 for the other side, and then remove the mid-
section lens(es).
Locate the lens latch on one end of the lightbar. Turn the latch
90° counter clockwise to release.
Tip: Where the end and mid-section lenses meet, gently press
both sides of the end lens inward to release the retaining
clips.
Tilt and lift the end lens to remove it from the chassis.
12
34
Open
Position
Retaining
Clip

19ENGLISH
Installing the Lens
Ensure the lens latches are in the open position. Install one of the end lenses, making
sure the lens edge and retaining clips are seated properly. Turn the lens latch 90°
clockwise to secure.
Install the mid-section lenses, making sure this lens is completely within the slot on the
end lens. For four-piece lenses, install the center bafe and the second mid-section lens
in the same manner.
Install the other end lens, making sure the lens edge and clips are seated properly. The
mid-section lens must be seated in the slot on the end lens.
Apply gentle downward pressure at each joint to ensure lenses are properly seated in
the chassis.
Turn the lens latch 90° clockwise to secure.
MAINTENANCE
Occasional cleaning of the lenses will ensure optimum light output. Take care when cleaning lenses
– although tough, polycarbonate can scratch. Clean the lens and base with soap and water or a lens
polish using a soft cloth. Do not use solvents as they may damage the polycarbonate. Do not subject
the lightbar to high-pressure washers or automatic car washers.
1
2
3
4
5
ASSEMBLY &
CONFIGURATION
Lenses

20
INSTALLING DROPLOCK™LED MODULES
DropLockTM LED modules are designed for simple, no-tool installation. During module installation, ensure the chassis is
disconnected from the power source. Each LED module base is marked with a single and a double contact indicator. Care must
be taken to ensure proper orientation of the contact indicators for each type of module where shown in this manual.
Directional Modules
EZ1401X
The EZ1401 LED directional module provides 120º high-intensity warning capability. Install these modules in the front or rear
DropLockTM power rails only. Use the keypad controller to select desired ash patterns (page 15).
Remove the lenses (page 18) to access the DropLockTM power
rail system. For standard operation, install the directional
module base in the front or rear DropLock™ power rails.
Rotate the top of the module to the desired angle. For correct
operation the single contact indicator on the base of the
module must face towards central control board.
12
FRONT
Single Contact Indicator