Federal Signal Corporation HighLighter Assembly instructions

2562495C
REV. C 811
Printed in U.S.A.
Installation and Programming
HigHLigHter™ LED Mini-Lightbars

HigHLigHter is a trademark of Federal Signal Corporation.
FAStON is a registered trademark of Tyco Electronics AMP Corp.
© 2011 Federal Signal Corporation

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Contents
Safety Message to Installers and Service Personnel of Warning Light Equipment.....................5
Safety Message to Operators of Warning Light Equipment.............................................................................7
Introduction.........................................................................................................................................9
Unpacking the Product ......................................................................................................................9
Product Specications.......................................................................................................................9
Permanently Mounting the HigHLigHter LED on the Vehicle .........................................................10
Preparing the Mounting Surface.....................................................................................................................10
Wiring the HigHLigHter LED ..............................................................................................................11
Accessing the Wiring......................................................................................................................................11
Completing the Wiring ...................................................................................................................................12
Completing the Installation Directly to the Vehicle .......................................................................13
Using Magnetic or Magnetic/Suction Mounting ............................................................................14
Selecting a Flash Pattern.................................................................................................................14
Selecting a Pattern Using the Jumper Pins.....................................................................................................16
Selecting a Pattern Using a Magnet Over the Hall-Effect Sensor..................................................................17
Cleaning the Plastic Dome ..............................................................................................................17
Ordering Replacement Parts...........................................................................................................18
Getting Technical Support and Service..........................................................................................18
Returning a Product to Federal Signal...........................................................................................18
Tables
Table 1 Mounting hardware.................................................................................................................9
Table 2 Flash patterns for standard 12 V HigHLigHter models..........................................................15
Table 3 CAC Title 13 ash patterns for amber models......................................................................16

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HigHLigHter™ LED Mini-Lightbars
Figures
Figure 1 Mounting holes for Patterns A and B...........................................................................................11
Figure 2 Upper assembly removed from lightbar base ..............................................................................12
Figure 3 Fuses, connectors, and programming jumper pins (PROG)........................................................13
Figure 4 Hole for Hall-effect sensor on PCB.............................................................................................17

HigHLigHter™ LED Mini-Lightbars
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Safety Message to Installers and Service Personnel of
Warning Light Equipment
People’s lives depend on your proper installation and servicing of Federal Signal products. It is
important to read and follow all instructions shipped with this product. In addition, listed below are
some other important safety instructions and precautions you should follow:
NOTE: The term “vehicle” in this publication refers to both automotive and marine watercraft.
Before Installation or Service
Qualications
• To properly install or service this equipment, you must have a good understanding of automotive
and marine mechanical and electrical procedures and systems, along with prociency in the
installation and service of safety warning equipment. Always refer to the vehicle’s service
manuals when performing equipment installations on a vehicle.
Light Hazards
• To be an effective warning device, this product produces bright light that can be hazardous to
your eyesight when viewed at a close range. Do not stare directly into this lighting product at a
close range or permanent damage to your eyesight may occur.
• Do not install the light system in an area that would block, impair or blind the driver’s vision.
Ensure that the light system is mounted in a position that is outside of the driver’s eld of vision,
so the driver can maintain safe vehicle operation.
• Federal Signal power supplies and light heads are designed to work together as a system.
Combining light heads and a power supply from different manufacturers may reduce the warning
effectiveness of the lighting system and may damage the components. You should verify or
test your combination to ensure the system works together and meets federal, state, and local
standards or guidelines.
Electrical Hazards
• Strobe systems present a shock hazard because they use high voltage to operate. Do not
handle strobe cables, the power supply or bulbs or remove the lens while the equipment is
connected. Strobe systems can also hold their charge even after they have been turned off. After
disconnecting power to the unit, wait ve minutes before handling any parts of the strobe system.
• A light system is a high current system. In order for the system to function properly, a separate
negative (–) connection and positive (+) connection must be made. All negative connections
should be connected to the negative battery terminal and a suitable fuse should be installed on the
positive battery terminal connection as close to the battery as possible. Ensure that all wires and
fuses are rated correctly to handle the device and system amperage requirements.
• Never attempt to install aftermarket equipment that connects to the vehicle wiring without
reviewing a vehicle wiring diagram available from the vehicle manufacturer. Ensure that your
installation will not affect vehicle operation or mandated safety functions or circuits. Always
check the vehicle for proper operation after installation.

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HigHLigHter™ LED Mini-Lightbars
• The lighting system components, especially light bulbs, strobe tubes, LEDs, and the outer
housing, get hot during operation. Be sure to disconnect power to the system and allow the
system to cool down before handling any components of the system.
• Halogen light bulbs and strobe tubes are pressurized and if broken, can burst and result in ying
glass. Always wear gloves and eye protection when handling these components.
• Do not mount a radio antenna within 18 inches (45.7 cm) of the lighting system. Placing the
antenna too close to the lighting system could cause the lighting system to malfunction or be
damaged by strong radio elds. Mounting the antenna too close to the lighting system may also
cause the radio noise emitted from the lighting system to interfere with the reception of the radio
transmitter and reduce radio reception.
• Do not attempt to wash any unsealed electrical device while it is connected to its power source.
During Installation and Service
• DO NOT get metal shavings inside the product. Metal shavings in the product can cause the
system to fail. If drilling must be done near the unit, place an ESD-approved cover over the unit.
Inspect the unit after mounting to be sure there are no shavings present in or near the unit.
• DO NOT connect this system to the vehicle battery until ALL other electrical connections are
made, mounting of all components is complete, and you have veried that no shorts exist. If
the wiring is shorted to the vehicle body or frame, high current conductors can cause hazardous
sparks resulting in electrical res or ying molten metal.
• DO NOT install equipment or route wiring (or the plug in cord) in the deployment path of an
airbag.
• Before mounting any components, check the manual to be sure that the component you are
installing is suitable for use in that area of the vehicle. Many components are not suitable for use
in the engine compartment or other extreme environmental exposure areas.
• Service life of light bulbs and strobes tubes will be shortened if the glass portion is touched
during installation. Use gloves when handling these components. If the glass portion has been
touched, clean the glass carefully with isopropyl alcohol.
• When drilling into a vehicle structure, be sure that both sides of the surface are clear of anything
that could be damaged. Remove all burrs from drilled holes. To prevent electrical shorts,
grommet all drilled holes through which wiring passes. Also, ensure that the mounting screws do
not cause electrical or mechanical damage to the vehicle.
• Refer to the manual packed with the lighting system for proper electrical connections, additional
precautions and information.
• Because vehicle roof construction and driving conditions vary, do not drive a vehicle with
a magnetically mounted warning light installed. The light could y off the vehicle causing
injury or damage. Repair of damage incurred because of ignoring this warning shall be the sole
responsibility of the user.
• To avoid denting the roof of the vehicle, place the lightbar mounting feet as close to outer edge of
the roof as possible.

HigHLigHter™ LED Mini-Lightbars
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• If a vehicle seat is temporarily removed, verify with the vehicle manufacturer if the seat needs to
be recalibrated for proper airbag deployment.
• Locate the light system controls so the VEHICLE and CONTROLS can be operated safely under
all driving conditions.
After Installation or Service
• After installation, test the light system to ensure that it is operating properly.
• Test all vehicle functions, including horn operation, vehicle safety functions and vehicle light
systems, to ensure proper operation. Ensure that the installation has not affected the vehicle
operation or changed any vehicle safety function or circuit.
• Scratched or dull reectors, mirrors or lenses will reduce the effectiveness of the lighting system.
Avoid heavy pressure and use of caustic or petroleum based products when cleaning the lighting
system. Replace any optical components that may have been scratched or crazed during system
installation.
• Do not attempt to activate or de-activate the light system control while driving in a hazardous
situation.
• You should frequently inspect the light system to ensure that it is operating properly and that it is
securely attached to the vehicle.
• After installation and testing are complete, provide a copy of these instructions to instructional
staff and all operating personnel.
• File these instructions in a safe place and refer to them when maintaining and/or re-installing the
product.
Failure to follow all safety precautions and instructions may result in property damage, serious
injury, or death to you or others.
RETAIN AND REFER TO THIS MESSAGE
Safety Message to Operators of Warning Light Equipment
People’s lives depend on your safe use of our products. Listed below are some important safety
instructions and precautions you should follow:
• Do not attempt to activate or de-activate the light system control while driving in a hazardous
situation.
• Although your warning system is operating properly, it may not be completely effective. People
may not see or heed your warning signal. You must recognize this fact and continue driving
cautiously.
• Also, situations may occur which obstruct your warning signal when natural and man-made
objects are between your vehicle and others, such as raising your hood or trunk lid. If these
situations occur, be especially careful.

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HigHLigHter™ LED Mini-Lightbars
• All effective sirens and horns produce loud sounds which may cause, in certain situations
permanent hearing loss. You and your passengers should consider taking appropriate safety
precautions such as wearing hearing protection.
• In order to be an effective warning device, this product produces bright light that can be
hazardous to your eyesight when viewed at a close range. Do not stare directly into this lighting
product at a close range or permanent damage to your eyesight may occur.
• It is important that you fully understand how to safely operate this warning system before use.
• You should only operate your vehicle and its light/sound system in accordance with your
department’s Standard Operating Procedures.
• If a selected function does not perform properly or if any of the lamps remain illuminated when
the control is off, disconnect the power connector from the control unit and contact the nearest
service center.
• At the start of your shift, you should ensure that the entire warning light system and the siren
system is securely attached and operating properly.
• Suction cup mounting is for temporary applications only. The unit should be removed from
the window and stored securely when not in use. Temperature changes and sunlight can cause
suction cups to lose holding power. Periodically check the unit to be sure the suction cups have
a rm grip on the mounting surface. An improperly secured light could fall off of the vehicle
causing injury and damage.
• The holding power of magnetic mounting systems is dependent upon surface nish, surface
atness, and thickness of the steel mounting surface. Therefore, to promote proper magnetic
mounting:
✓The mounting surface and magnets must be kept clean, dry, and free of foreign particles that
prevent good surface contact.
✓ Ensure that the mounting surface is at.
✓A magnet mounting system should not be used on vehicles with vinyl tops.
✓To prevent the sliding of the lightbar on the mounting surface, quick acceleration and hard
stops should be avoided.
Failure to follow these precautions may result in property damage, serious injury, or death.
RETAIN AND REFER TO THIS MESSAGE

HigHLigHter™ LED Mini-Lightbars
9
Introduction
This manual provides instructions for the installation, wiring, and maintenance of the HigHLigHter LED
Mini-Lightbar. The HigHLigHter LED is a high-performance warning light with a small outline and low
current draw. The HigHLigHter LED is designed to control or be controlled as part of a greater lighting
system. The active ash pattern can be selected from the 19 available.
Unpacking the Product
After unpacking the product, inspect it for damage that may have occurred in transit. If the product has
been damaged, do not attempt to install or operate it. File a claim immediately with the carrier, stating the
extent of damage. Carefully check all envelopes, shipping labels, and tags before removing or destroying
them. Ensure that the parts listed in the KIT CONTENTS LIST are contained in the packing carton.
Table 1 Mounting hardware
Qty. Description Part Number
4 Screw, Thd. Form., 1/4" 7011A158-12
1 Grommet 8108A002
1 Foam Mounting Pad 8560102
Product Specications
Dimensions Current Draw
Length: 15.30 in (38.86
cm)
HigHLigHter only:
Width: 8.40 in (21.34 cm) 12 V HigHLigHter:5 A maximum
Height:Fuse Ratings
Permanent Mount: 2.66 in (6.76 cm) HigHLigHter Fuse: 7.5 A (internal)
With Flat Mount Brack-
ets:
3.13 in (7.94 cm) Main Power Connection: 15 A recommended
(installer supplied)
Magnetic Mount: 3.03 in (7.70 cm)
Suction Cup Mount: 3.00 in (7.62 cm)
Weight:
Permanent Mount: 3.40 lb (1.54 kg)
Magnetic Mount: 4.50 lb (2.04 kg)
Suction Cup Mount: 6.00 lb (2.72 kg)

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HigHLigHter™ LED Mini-Lightbars
Permanently Mounting the HigHLigHter LED on the Vehicle
AIRBAG DEPLOYMENT
Do not install equipment or route wiring in the deployment of an airbag.
Failure to observe this warning will reduce the effectiveness of the airbag or potentially dislodge the
equipment, causing serious injury.
FLAT MOUNT BRACKETS
Curved mounting locations may distort the base of the lightbar if the mounting screws are over-
tightened. To prevent the base from being distorted, use the Flat Mount Brackets. They are
available separately as Federal Signal part number 454218.
DRILLING PRECAUTIONS
Before drilling holes, check the area into which you plan to drill to ensure you do not damage
vehicle components while drilling. All drilled holes should be deburred and all sharp edges should
be smoothed. All wires going through drilled holes should be protected by a grommet or convolute/
split-loom tubing.
The lightbar is completely wired at the factory and does not require any additional internal wiring. User-
supplied 18 AWG or larger wire may be added if required. Optional 15-foot cable kits are available from
your dealer or Federal Signal. See “Ordering Replacement Parts” on page 18.
Before beginning any installation, plan the wiring path and mounting method. Depending on the number
of lightbars installed and the distance between connection points, you may need to install heavier gauge
wire.
Preparing the Mounting Surface
Select a relatively at and level position on the mounting surface. Figure 1 shows two patterns of
mounting holes.
• Pattern A matches the holes on the Halogen and Strobe HigHLigHter LED models.
• Pattern B is an alternate set of holes that are closer to the corners for greater stability.
NOTE: Install the lightbar with the notch in its base facing the rear of the vehicle.