Federal Signal Corporation RAYDIAN User manual

2561898G
REV. G 1006
Printed in U.S.A.
INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR
RAYDIAN® LED LIGHTBAR
SAFETY MESSAGE TO INSTALLERS AND USERS
People’s lives depend on your safe installation
of our products. It is important to read, under-
stand and follow all instructions shipped with
the products. In addition, listed below are some
other important safety instructions and precau-
tions you should follow:
• To properly install lightbar, you must have
a good understanding of automotive sys-
tems, along with proficiency in the installa-
tion and use of safety warning equipment.
• DO NOT install equipment or route wiring
in the deployment path of an air bag.
• This product contains high intensity LED
devices. To prevent permanent eye damage,
DO NOT stare into the light beam at close
range.
• A light system is a high current device. In
order for it to function properly, a separate
ground connection must be made. If practi-
cal, it should be connected to the negative
battery terminal. At a minimum, it may be
attached to a solid metal body or chassis
part that will provide an effective ground
path as long as the light system is used.
• When drilling into a vehicle structure, be
sure that both sides of the surface are clear
of anything that could be damaged.
• Locate the light system controls so the
VEHICLE and CONTROLS can be operated
safely under all driving conditions.
• The mounting system should be periodi-
cally inspected to ensure that it is securely
attached to the vehicle.
• File these instructions in a safe place and
refer to them when maintaining and/or
reinstalling the product.
Failure to follow all safety precautions and instruc-
tions may result in property damage, serious injury, or
death to you or others.
I. GENERAL.
HEAVY OBJECT
Get assistance when lifting or installing.
Failure to do so will cause permanent bodily
injury.
The Raydian is a LED light bar, with supplemental white
halogen area lighting, designed for use with Federal Signal
lightbar controllers and/or single switches rated at 2-amperes
and above. The base is a two piece extruded aluminum profile
with polycarbonate lenses and end domes. The unit is supplied
with mounting hardware and an eighteen-foot cable and has
an operating temperature of -40°C to +65°C.
II. UNPACKING.
After unpacking the Raydian light assembly, inspect it for
damage that may have occurred in transit. If the unit 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.
III. INSTALLATION.
A. General.
Before proceeding, ensure that the lightbar has been
installed on the vehicle roof in accordance with the instruc-
tions packed with the mounting kit. The lightbar is completely
wired at the factory and does not require any additional inter-
nal wiring. All the conductors necessary for control of any and
all basic and optional functions are contained in the cable. The
basic light functions of the unit must be controlled by a user-
supplied control head.
Light system controls must be located so that
the VEHICLE and CONTROLS can be operated
safely under all driving conditions.
1. Route the control cable into the vehicle and near
the eventual location of the user-supplied control head. Route
the Power cable into the vehicle and to the battery.
2. For proper light operation, the control cable must
be properly terminated inside the user-supplied control head.
Using figure 1 and table 1 as a guide, make the appropriate
electrical connections. Ensure that the lines are adequately
fused as shown and that the switch capacity is adequate for
the current requirement.
Reverse polarity may damage any power supply and
prevent operation. Ensure that the correct polarity is
observed. The positive (+) power lead must be fused at
the source for 40 amps.
3. Connect the separate 10 gauge black lead to the
vehicle battery ground terminal (-) and the separate 10 gauge
red lead to the vehicle battery hot terminal (+).
NOTE
All the lightbar functions can be activated by applying
12VDC to the appropriate control line. The 10 gauge
black and red power leads must be connected to their
respective battery terminals for a function check.

C0NROL CABLE MAIN FUNCTIONS SM INTERNAL SS2000SM* 330132/330102* 331112/331102*
WHT/RED MODE 3 MODE 3 MODE 3 MODE 3 MODE 3
RED MODE 2 MODE 2 MODE 2 MODE 2 MODE 2
WHT/ORG MODE 1 MODE 1 MODE 1 MODE 1 MODE 1
ORG STEADY RED STEADY RED STEADY RED STEADY RED STEADY RED
WHT/YEL INTERSECTION INTERSECTION INTERSECTION INTERSECTION INTERSECTION
YEL FLASH A&TD FLASH A & TD FLASH A & TD FLASH A & TD FLASH A & TD
BLK/PNK F_ CUT OFF F_ CUT OFF F_ CUT OFF F_ CUT OFF F_ CUT OFF
BLK N/C N/C N/C N/C N/C
WHT/BLK PROGRAM PROGRAM PROGRAM PROGRAM PROGRAM
GRN RIGHT ALLEY RIGHT ALLEY RIGHT ALLEY RIGHT ALLEY RIGHT ALLEY
WHT LEFT ALLEY LEFT ALLEY LEFT ALLEY LEFT ALLEY LEFT ALLEY
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 WARN 1 (5) VIO VIO
WHT/BLU N/C WARN 2 (4) ORG ORG
BLU N/C WARN 3 (3) GRN GRN
WHT/GRN N/C WARN 4 (2) BRN BRN
WHT/GRY N/C SPEED (1) WHT WHT
Table 1
Figure 1.
B. Function Activation – Excluding
SignalMaster™.
NOTE
Refer to table 1 and figure 1 for proper connections.
NOTE
Powering multiple devices with a common control
lead may cause one or more units to briefly remain
functional after signal power is removed. For example,
due to the high input filter capacitance, a strobe sup-
ply can briefly supply the current required to operate
a low current device such as a Cuda TriOptic™. If
necessary, use a relay to isolate devices with large
filter capacitors. See figure 2 for the schematic; all
components/wires are user-supplied.
1. Mode Inputs.
There are three prioritized mode of operation
available with mode three being the highest priority. Mode 3
(WHT/RED) will override Mode 2 (RED) and Mode 2 will over-
ride Mode 1 WHT/ORN). One of the available flash patterns
can be programmed to each mode input. Default configuration
is Mode 3 Random Flash, Mode 2 Quad Flash and Mode 1 595
Flash. Programming will be covered later in this section. To
activate a mode, apply 12VDC to a mode input wire. 12VDC
must also be applied to the front cutoff wire (BLK/PNK) for the
front of the bar to operate. See figure 1 for proper fusing.
-2-
* 42” Raydian with 7-head SignalMaster - Use SS2000SM set to 6-head, 330132, or 331112.
54” Raydian with 8-head SignalMaster - Use SS2000SM set to 8-head, 330102, or 331102.
290A4744C
WHT/RED
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
1 A
MODE 3
RED MODE 2
WHT/ORN MODE 1
ORANGE STDY BURN RED
WHT/YEL INTERSECTION
YELLOW FLASH TD'S/ALLEYS
BLK/PNK FRONT CUT OFF
GREEN RIGHT ALLEY
WHITE LEFT ALLEY
1 A GRAY TAKE DOWNS
WHT/BRN SM INT LEFT/SM EXT (S2000 8) (SMC BLU)
BROWN SM INT CENTER/SM EXT (S2000 7) (SMC YEL)
WHT/VIO SM INT RIGHT/SM EXT (S2000 6) (SMC GRY)
VIOLET SM INT WARN1/SM EXT (S2000 5) (SMC VIO)
WHT/BLU SM INT WARN2/SM EXT (S2000 4) (SMC ORG)
BLUE SM INT WARN3/SM EXT (S2000 3) (SMC GRN)
WHT/GRN SM INT WARN4/SM EXT (S2000 2) (SMC BRN)
40 A
WHT/GRY SM INT FAST/SM EXT (S2000 1) (SMC WHT)
(+) POWER/IGN
20 COND 22 AWG CABLE
(+) BATTERY
(–) GROUND
(–) BATTERY
(+) BATTERY

-3-
Figure 2.
290A4863
CUDATRIOPTIC
+12V
CONTROL LEAD
(12V SIGNAL ACTIVATED)
RELAY
FUSE
STROBE SUPPLY
2. Steady Burn Red.
When the Raydian is equipped with a Steady
Burn Red led module, applying 12VDC to the Orange wire will
cause that module to operate when any mode input is selected.
3. Intersection Mode.
When 12VDC is applied to the WHT/YEL wire, it
will cause the flash rate of the selected mode input to double.
When 12VDC is removed, the flash rate will return to normal.
See paragraph III.B.10 Additional Programming for alterna-
tive configurations of this feature.
4. Flash Alley’s and Takedowns.
Applying 12VDC to the Flash Alley’ & Take-
downs (YEL) wire will cause the halogen Alley and Takedown
lights to flash when a mode input is selected. See paragraph
III.B.10 Additional Programming for alternative configurations
of this feature.
5. Front Cut Off.
Applying 12VDC to the Front Cut Off (BLK/
PNK) wire will cause the front of the bar to operate, when a
mode input is selected. If Front Cut Off is not active only the
rear and rear portion of the end cap LED’s will function. Addi-
tionally if Flash Alley’s & Takedowns is active, only the alley’s
will flash. See paragraph III.B.10 Additional Programming for
alternative configurations of this feature.
6. Right Alley.
Applying 12VDC to the Right Alley (Green) wire
will cause the Right Alley lights to illuminate.
7. Left Alley.
Applying 12VDC to the Left Alley (White) wire
will cause the Left Alley lights to illuminate.
8. Takedowns.
Applying 12VDC to the Takedowns (Gray) wire
will cause the Takedowns lights to illuminate.
9. Main Mode Programming.
Each of the three modes of operation can be
programmed to operate with one of the fifteen available flash
patterns listed below (see figure 3):
• 1 - Random
• 2 - Quad
• 3 - SAE J595 Flash
• 4 - Action
• 5 - Center Sweep
• 6 - Action Center/Sweep
• 7 - Random / End Caps Sweep
• 8 - Modulate
• 9 - Rear Alternating
• 10 - Rear Quad
• 11 - Front Feet Alternating
• 12 - Front Feet & Front Modules Alternating
• 13 - K&O / JJ&PP Alternating 75FPM
• 14 - J / P Alternating 75FPM
• 15 - J, BB, CC, DD, JJ, KK, LL, MM / P, FF, GG,
HH, PP, OO, NN Alternating 75FPM
Programming is accomplished as follows:
a. Apply 12VDC to the mode input to be pro-
grammed. The bar will flash the current pattern.
b. Momentarily apply 12VDC to (WHT/BLK)
Program wire. The light bar will stop briefly, then the end cap
LED’s will flash the number of the new flash pattern. The light
bar will then begin to flash the newly selected pattern.
c. Repeat step 2 until the desired pattern is
selected.
d. To program the other modes, apply 12VDC
to the desired mode input and repeat steps 2 and 3.
10. Additional Programming.
The following user programmable features are
also available:
a. Front Cut Off .
The Default setting is that the front of the
bar is active when 12 VDC is applied to the BLK/PINK control
input wire. This configuration can be reversed so that the front
of the bar is deactived when 12 VDC is applied to the BLK/
PINK control input wire. To change the configuration, perform
the following programming steps:
• With all power removed from the 10GA
RED power lead and control input wires, apply 12 VDC to the
Program (WHT/BLK) and Front Cut Off (BLK/PNK) control
input wires.
Figure 3.
290A5343B
DRIVER FRONT OF BAR
SOLARIS END DOMES
FRONT OF BAR
TRIOPTIC END DOMES
DRIVER
PASSENGER
PASSENGER
LF
LR
RF
RR
RF
RR
LF
LR
A
CC
C
J K L M N O P
JJ KK LL MM NN OO PP
JJ KK LL MM NN OO PP
J K L M N O P
G
GG
E
H
G
F
E
FF
GG
HH
D
C
B
A
BB
CC
DD

-4-
• Apply 12 VDC to the 10GA RED power
lead. One half of the front of the lightbar will light steady to
indicate which configuration is selected (driver side - 12 VDC
activate / passenger side 12 VDC deactivate).
• To change the configuration, momentarily
apply 12 VDC to the Flash Alleys & Takedowns (YEL) control
input. The configuration will switch to the opposite mode, and
the opposite half of the front of the lightbar will light steady.
• The configuration will change each time 12
VDC is momentarily applied to the YEL control input wire.
• When programming is completed, remove
12 VDC from all circuits. Ensure all leads are properly con-
nected and test for proper operation.
b. Intersection Mode.
The Default setting is that Intersection
mode is activated when 12 VDC is applied to the Intersection
(WHT/YEL) control input wire, and deactivated when 12 VDC
is removed from the WHT/YEL control input wire. This con-
figuration can be changed so that Intersection mode is a TAP II
function, where 12 VDC is momentarily applied to the WHT/
YEL control input wire to activate Intersection mode, then 12
VDC is again momentarily applied to the WHT/YEL control
input wire to deactivate. To change the configuration, perform
the following programming steps:
• With all power removed from the 10GA
RED power lead and control input wires, apply 12 VDC to Pro-
gram (WHT/BLK) and Intersection (WHT/YEL) control input
wires.
• Apply 12 VDC to the 10GA RED power
lead. One of the end caps of the lightbar will light steady to
indicate which configuration is selected (passenger side - 12
VDC active / driver side — TAP II).
• To change the configuration, momentarily
apply 12 VDC to the Flash Alleys & Takedowns (YEL) control
input. The configuration will switch to the opposite mode, and
the opposite end cap of the lightbar will light steady.
• The configuration will change each time 12
VDC is momentarily applied to the YEL control input wire.
• When programming is completed, remove
12 VDC from all circuits. Ensure all leads are properly con-
nected and test for proper operation.
c. Flash Alleys & Takedowns - The Default
setting is that both Alleys & Takedowns flash when 12VDC is
applied to the Flash Alleys & Takedowns (YEL) control input.
This configuration can be changed to Flash Takedowns Only
when 12VDC is applied to the YEL control input . To change
configuration, perform the following programming steps:
• With all power removed from the 10GA
RED power lead and control input wires, apply 12 VDC to the
Program (WHT/BLK) and Flash Alleys & Takedowns (YEL)
control input wires.
• Apply 12 VDC to the 10GA RED power
lead. The driver side end cap will light steady if Flash Alleys
& Takedowns is selected. The front of the lightbar will light
steady if Flash Takedowns Only is selected.
• To change the configuration, momentarily
apply 12 VDC to the Steady Red (ORG) control input wire. The
configuration will switch to the opposite mode, and the alter-
nate indicator will light steady.
• The configuration will change each time 12
VDC is momentarily applied to the ORG control input wire.
• When programming is completed, remove
12 VDC from all circuits. Ensure all leads are properly con-
nected and test for proper operation.
After all programming is completed, insulate or
trim the (WHT/BLK) Program wire and secure it to prevent
accidental pattern changes.
C. Function Activation – SignalMaster.
NOTE
Jumpers are factory installed for External SignalMas-
ter Controller.
Refer to table 1 and figures 1 and 4 for proper connec-
tions.
1. SignalMaster Internal Controller.
a. See figure 5. Ensure that jumpers JP2 &
JP7 are installed as indicated
b. When 12VDC is applied to one of the input
wires the corresponding SignalMaster function will activate
(see table 1). The first seven inputs are prioritized, with “Left”
(WHT/BRN) being the highest priority and “Warn 4” (WHT/
GRN) being the lowest priority. The highest priority input
that has 12VDC applied will override any other input that
has 12VDC applied. When using a three position progressive
slide switch for “Left”, “Center” and “Right” functions, “Left” is
connected to position one “Center” to position two and “Right to
position three. The “Fast” (WHT/GRY) input will cause the Sig-
nalMaster to operate at twice the normal speed, when 12VDC
is applied to the input.
2. SignalMaster External Controller.
a. See figure 6. Ensure that jumpers JP2 &
JP7 are installed as indicated.
b. Refer to table 1 and connect the SignalMas-
ter input wires to the corresponding connections of the Signal-
Master controller.
J17
R30
Q2
+
R40
H3
H2
H4
F7
R55
+ +
Q-
F6
J12
+
P-O- + N-
C28
F5 D10
C33
F4
F3
C20
+
Q6
+D4
+
F2
U5
F1
C21
J10
R41
Q8
-
J13
+
M-L-
U8
+K- + J
J14
GG
HH EFF F HG NM -
U9
UPPER TAKEDOWNS
ALLEY- -
J15
++
Q9
J16
ORG
WHT
+SR -
R46
Q7
J11
R29
Q4
ALLEY
J9
A
+
C10
D2
-
U1
D C B
R6
R15
+
J1
BB CC DD
J2
+
JP4
MADE IN U.S.A.
UNIVERSITY PARK,IL
FEDERAL SIGNAL CORP.
2005245A-
-
J3
JJ
Q1
- - - + - KK +
1 2
JP3
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
C49
D21
RSB
R51 R52
J18
C46
SR+ -
J19
C47
C42
D19
D18
C43
D20
R53
SIGMAST INPUTS
FSB
C48
J20
U10
R47
C44
R48
C45
MAIN PROG
J21
R50
JP7
R49
R54
D22
C50
C24
R33R32
D17
D12
D14 D15
D11
D16
U6
D7
D5
D6 D8 D9
C38
R42
C34
D13
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
D3
C25
C19C18
C26
R28
C14
R27
C13
JP6
Y1
C15
C27
C9
R23
R16
PATTERN INPUTS
J7
RIGHT
ALLEYS
RIGHT
TAKEDOWNS
LEFT
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
C52
C51
U4
R10
290A4745
Figure 4.

-5-
IV. TESTING.
This product contains high output LED devices.
To prevent permanent eye damage, do not stare
into the light beam at close range.
After Installation, check the entire system to be sure the
lights are flashing properly and all light system functions are
operating properly.
SAFETY MESSAGE TO OPERATORS
People’s lives depend on your safe use of our
products. Listed below are some important
safety instructions and precautions you should
follow:
• 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 or man-
made objects are between your vehicle and
others, such as: raising 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 attached and oper-
ating properly.
Failure to follow these safety precautions may re-
sult in property damage, serious injury, or death to you,
to passengers, or to others.
RETAIN AND REFER TO THIS MESSAGE
V. MAINTENANCE.
Crazing (cracking) of lenses will cause reduced
effectiveness of the light. Do not use cleaning
agent (which will cause crazing) such as strong
detergents, solvents, or petroleum products.
If crazing of lenses does occur, reliability of
light for emergency signaling purposes may be
reduced until lenses are replaced.
High voltages are present inside the lightbar.
Wait at least 10 minutes after shutting off the
power before servicing the unit. Disconnect
ALL power to the lightbar before any mainte-
nance is performed. Failure to do so may result
in property damage, serious injury, or death to
you or others.
CAUTION
After prolonged operation, the unit gets hot and can
cause burns. Do not touch the unit while or shortly
after it has been operating. Always allow the unit to
cool before handling.
A. General.
Ordinary cleaning of the plastic lenses can be ac-
complished by using mild soap and a soft rag. Should fine
scratches or a haze appear on a lens, they can best be removed
with a specialty plastic cleaner/polish such as Plexus® and a
soft cloth. Alternatively, non-abrasive, high quality, one-step,
automotive past cleaner/wax may be used.
B. Outer Lens Removal (see figure 7).
Remove the end dome, then starting at one end, pop
the bottom of the lens off the lower extrusion. The preferred
method is to apply pressure to the center of the lens with the
thumb of one hand while the fingers of that hand snap the lens
from the extrusion. Alternatively, a small, flat-bladed screw-
driver may be used to carefully pry the lens from the extru-
sion, ensuring that the lens and the underlying o-ring cord are
not damaged. Once the end is free, the lens can be peeled off
the bar. To install the lens, hook the upper edge into its o-ring
groove then snap the lower edge into position. Seal the end of
the lens/extrusion joint with RTV as shown.
C. End Dome Lamp Service (see figure 8).
1. Removal.
Remove the two 1/4-20 Phillips Flathead screws re-
taining the dome assembly. Slide the assembly away from the
bar and unplug the 15 pin electrical connector. With the end
dome removed from the bar, remove the 10-32 Phillips head
screw from the bottom of the dome. The lighting units, upper
plate, and lower plate are removed from the dome as an assem-
bly. Once free of the dome, the top plate and lighting units lift
free of the bottom plate.
Figure 5.
JP2
JP7
290A4747
JP2
JP7
290A4746
Figure 6.

-6-
Figure 7.
290A4749
DOME
LIGHTING UNITS
UPPER PLATE
LOWER PLATE
#10-32 PHILLIPS
HEAD SCREW
Figure 8.
2. Installation.
Installation is the reverse of disassembly. Inspect
the dome seal for cuts or tears, replacing as necessary (see
paragraph VI. Replacement Parts). Inspect the self-clinching
nuts in the bottom plate to verify that they are not loose in
the plate and that the threads are not damaged. If either of
these conditions exist, replace the bottom plate (see paragraph
VI. Replacement Parts). When installing the lighting units,
pay attention to the locating slots, tabs, and bosses. The 10-32
Phillips screw and the two 1/4-20 Phillips Flathead screws
are coated at the factory with anti-seize compound to prevent
stainless galling. If the screws are cleaned or replaced apply
a tiny amount of anti-seize (user-supplied - Bostik Never-
Seez© is a commonly available brand) to the first two or three
threads. Before securing the Phillips head screw in the bottom
of the dome, ensure the holes for the dome mounting screws
are properly aligned in the dome, top plate, and bottom plate.
The dome seal must be compressed to provide a good seal, thus
pressure must be applied to the dome during installation. A
1/4” drift punch (or the 1/4” shank of a #2 Phillips screwdriver)
is used to align the holes in the dome, top plate, end bracket,
and bottom plate. While keeping slight pressure inward on
the dome, align both holes, leaving the drift in the second hole
while starting the screw in the first hole. Use due care when
starting the screws to prevent cross-threading. Start both
screws before securing either. Do not over tighten.
D. Halogen Lamp Replacement.
A serious injury may result if the lamp is
touched when hot. Always allow lamp to cool be-
fore removing. Halogen lamps are pressurized
and if broken can result in flying glass. Always
wear gloves and eye protection when handling
lamps.
Service life of the lamp will be shortened if the glass
portion is touched. If the glass has been handled,
clean carefully with a grease solvent.
See figure 9. Replace the defective lamp with an exact
replacement only (see paragraph VI. Replacement Parts.).
E. Main Bar Lighting Unit Service (see figures 7
and 10).
To remove a complete lighting unit from the main
bar, first remove the outer lens as detailed above. Remove the
retaining clip from both sides of the unit to be removed. Light
bars with 9-button Solaris™ reflectors have either one retain-
ing clip at each end of the bar or none at all, depending on
configuration. Note quantity and location prior to removal. A
small flat-bladed screwdriver may be used to release the tabs
on the clip. Slide the unit out of the bar and disconnect the
electrical connector. Installation is the reverse; the clips snap
into position with an audible click.
F. Cleaning Reflector Assemblies.
Use a soft tissue to clean reflectors. Avoid heavy
pressure and the use of caustic, abrasive, or petroleum-base
cleaners, which will scratch or dull the surface.
G. PCB Backer Board Assembly Replacement,
TriOptic LEDs (see figure 10).
1. Disconnect the electrical connector from the PCB
assembly
2. Gently pry the PCB assembly from the snap-top
standoffs on the backplane.
290A4755
BI-PIN, #GH-8, #GH-9
Figure 9.
RTV TOP VIEW
290A4748C
HOLLOW “O” RING
CORD RTV
LENS
SOLID “O” RING
CORD
END VIEW

-7-
Figure 11.
Figure 10.
3. Assembly is the reverse of disassembly. Prior to
installation of the PCB assembly, ensure that the LED connec-
tor pins on the PCB are not bent or damaged.
H. PCB Backer Board Assembly Replacement, Solaris
LEDs (see figure 11 or 12).
1. Remove the #6 Phillips head screw retaining the
PCB assembly.
2. Slide the PCB assembly up then away from the
reflector to disengage the pins from the LED.
3. Assembly is the reverse of disassembly. Prior to
installation of the PCB assembly, ensure that the LED connec-
tor pins on the PCB are not bent or damaged.
I. LED Module Replacement, TriOptic LEDs (see
figure 10).
1. Follow steps 1-2 of PCB Assembly Replacement.
If necessary, remove the complete light unit for access.
2. Remove and discard the Rivscrews retaining the
LED module to the backplane. Remove the module.
3. Unlatch the Fresnel lens from the LED module.
4. Snap the Fresnel lens onto the new module.
Make sure the rectangular recess in the lens aligns with the
black connector on the new LED module.
5. Position the LED module on the backplane,
aligning the black connector on the LED with the large clear-
ance hole in the backplane. Secure the module with the two
6-32 screws provided.
6. Assembly is the reverse of disassembly.
J. LED Module Replacement, Solaris LEDs (see
figure 11 or 12).
a. Follow steps a-b of PCB Backer Board Assembly
Replacement.
b. Release the two locking tabs by prying gently
while sliding aluminum baseplate forward.
c. Lift baseplate free and remove LED.
d. Assembly is reverse of disassembly.
K. Fresnel Lens Replacement (see figure 10).
Unlatch the Fresnel lens from the LED module. As-
sembly is the reverse.
L. PCB Motherboard Replacement (see figure 13).
1. Remove end dome as detailed above.
2. Remove the two 1/4-20 Hex Head screws, lock-
washers, washers, and the ground lead. Move end bracket
and dome seal aside without removing 15 pin connector from
bracket.
3. Slide PCB assembly from extrusion and invert.
4. Disconnect the electrical connectors from the
PCB assembly
5. Remove the six 6-32 Phillips screws and lock-
washers retaining the PCB. Note location of ground lead.
6. Assembly is the reverse of disassembly. Use care
when tucking harnesses into bar to avoid displacing fuses
from the motherboard. When installing the dome seal, the two
small holes in the face of the seal indicate “UP”. Do not pinch
harnesses between extrusion and dome seal or end bracket.
Reinstall ground lead.
290A4750
LED MODULE
FRESNEL LENS
BACKPLANE
ASSEMBLY
RIVSCREWS
PC BOARD
ASSEMBLY
BASEPLATE
REFLECTOR
LOCKING TAB
PCB ASSEMBLY
#6 PHILLIPS SCREW LED
290A5055

-8-
Figure 12.
Figure 13.
BASEPLATE
REFLECTOR
LOCKING TAB
PCB ASSEMBLY
#6 PHILLIPS
SCREW
LEDS
290A5054
290A4756B
1/4" FLAT WASHER
END BRACKET
ASSEMBLY
P.C.B. BOARD AND
BRACKET ASSEMBLY
EXTRUSION
1/4" LOCKWASHER
1/4-20 HEX
HEAD SCREW
DOME SEAL
VI. REPLACEMENT PARTS.
Description Part No.
PCB Assembly 3 PK Backer Board Z2005224-N
PCB Assembly 2 PK Backer Board Z2005223-N
PCB Assembly 1 PK Backer Board Z2005222-N
PCB Assembly Motherboard Z8654153-123
(No SignalMaster)
PCB Assembly Motherboard Z8654153-12
(With SignalMaster)
LED Module Assembly, Amber Z8625106-AS
LED Module Assembly, Blue Z8625106-BS
LED Module Assembly, Red Z8625106-RS
LED Module Assembly, White Z8625106-WS
Lens, Fresnel 8625101
Lamp, Halogen, 50W GH-8 Bi-Pin 8107169
Plate, End Dome, Bottom 8654106
Dome Seal 8654180
6 Button Solaris LED Assemblies
PCB Assembly 2005272-1 (to be
replaced by 2005340-1)
Reflector Assembly, 6 Button Amber 8654167-12
(includes PCB)
Reflector Assembly, 6 ButtonBlue 8654167-13
(includes PCB)
Reflector Assembly, 6 Button Red 8654167-14
(includes PCB)
Reflector Assembly, 6 Button White 8654167-15
(includes PCB)
LED, 6 Button, Amber 8625234-A
LED, 6 Button, Blue 8625234-B
LED, 6 Button, Red 8625234-R
LED, 6 Button, White 8625234-W
Reflector, 6 Button Polyparabolic 8654165
9 Button Solaris LED Assemblies
Description Part No.
PCB Assembly 2005291-1 (to be
replaced by 2005341-1)
Reflector Assembly, 9 Button Amber 8654183-12
(includes PCB)
Reflector Assembly, 9 Button Blue 8654183-13
(includes PCB)
Reflector Assembly, 9 Button Red 8654183-14
(includes PCB)
Reflector Assembly, 9 Button White 8654183-15
(includes PCB)
LED, 3 Button, Amber (3 req’d.) 8625106-A
LED, 3 Button, Blue (3 req’d.) 8625106-B
LED, 3 Button, Red (3 req’d.) 8625106-R
LED, 3 Button, White (3 req’d.) 8625106-W
Reflector, 9 Button Polyparabolic 8654175
Manufactured by:
Federal Signal Corporation
Emergency Products Group
2645 Federal Signal Drive
University Park, Illinois 60466
Copyright 2005 Federal Signal Corporation