Federal Signal Corporation SignalMaster 331105 SMC5 User manual

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 and the original product. In addition, listed below
are some other important safety instructions and precautions you should follow:
• Toproperlyinstallthisdevice,youmusthaveagoodunderstandingofautomotiveelectricalprocedures
andsystems,alongwithprociencyintheinstallationanduseofsafetywarningequipment.
• DONOTinstallequipmentorroutewiringinthedeploymentpathofanairbag.
• Ifavehicleseatistemporarilyremoved,verifywiththevehiclemanufactureriftheseatneedstobe
recalibrated for proper airbag deployment.
• Whendrillingintoavehiclestructure,besurethatbothsidesofthesurfaceareclearofanythingthat
could be damaged.
• Inorderforthedevicetofunctionproperly,agoodgroundconnectionmustbemade.Ataminimum,it
must be attached to a solid metal body or chassis part that will provide an effective ground path as long
as the light system is to be used.
• LocatelightcontrolsotheVEHICLEandCONTROLcanbeoperatedsafelyunderalldriving
conditions.
• Donotattempttoactivateordeactivatelightcontrolwhiledrivinginahazardoussituation.
• Thisproductcontrolshighintensitylightingdevices.Topreventeyedamage,DONOTstareintothe
light beam at close range.
• Youshouldfrequentlyinspectthelighttoensurethatitisoperatingproperlyand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 instructions may result in property damage, serious injury, or death.
Overview
TheModel331105,SMC5isafullfeatureddirectionallightcontrol.Itisdesignedtooperatethefull
selectionofFederalSignalSignalMaster®directional lights from four to eight heads (continuous or split) at
12Vor24V.Highcurrentswitchingabilityallowstwofull,eight-head,halogenSignalMasterstobedirectly
controlledbyasingle331105controller.Thecontrollerisprotectedagainstreversepolaritybya2Afuseand
adiode.EachSignalMasterlightbarrequiresaninstaller-supplied20Afuse.
Thismodelprovidessixdistinctivedirectionalsignals.Therearestandardleft-arrow,center-outandright-
arrowpatternsaswellasspecialleft-arrow,center-out,andright-arrowpatternsthatcomplywithCACTitle
13,Article22ifusedwiththeappropriateSignalMasterdirectionallightbarselectedfromthemodelsin
Tables1and2onpage2.
Instructions for the Model 331105 SMC5
SignalMaster® Lightbar Controller
2562119D REV. D 911

Installation and Programming Instructions
2Model 331105 SMC5 SignalMaster Controller
Table 1 Halogen SignalMaster directional warning lights
(for CAC Title 13, Article 22 compliance)
Model Length Lamps Cable Lenses
320142 20 in 4 30 ft Amber
320162 31 in 6 15 ft Amber
320612 31 in 6 30 ft Amber
320172 42 in 8 15 ft Amber
320182 42 in 8 30 ft Amber
320192 42 in 8 50 ft Amber
320602 84 in 8+ DOT Strip 35 ft Amber
Table 2 VPX SignalMaster directional warning lights
(for CAC Title 13, Article 22 compliance)
Model Length Lamps Cable LEDs Lenses
320900 20 in 4 30 ft Amber Amber
320905 31 in 6 15 ft Amber Amber
320910 31 in 6 30 ft Amber Amber
320915 31 in 6 60 ft Amber Amber
320920 42 in 8 15 ft Amber Amber
320925 42 in 8 30 ft Amber Amber
320930 42 in 8 60 ft Amber Amber
320935 51 in 8 30 ft Amber Amber
320940 51 in 8 50 ft Amber Amber
TheWARNfunctionprovidesanon-directionalashpatternforusewhenadirectionalsignalmaynotbe
appropriate.Onepatterncanbeselectedfromthe16patternsavailable,whichinclude13standardpatterns
andthreepatternscompliantwithCACTitle13,Article22.SomepatternsareoptimizedforLEDproducts
andashtoofastforahalogenlightbar.ThedefaultpatternistheclassicSMCwarnpatternwiththecenter
lightheads alternating with the lightheads on each end.
TheAUXfunctionprovidesaninstaller-selectableashpatternfortwoauxiliarylightheads.TheAUX
functionoperatesexternallamps(ifinstalled)independentlyonlyifoneoftheveavailablepatternsother
thanPattern6(allon)ornullisselected(Table6onpage11.)Eachofthetwoauxiliarychannelscanasha
55Wload.Apatternwiththeoutputssettoremainonconstantlyisavailable.Thiswillallowapairofstrobe
beaconsorsimilardeviceswithaninternalashertobeturnedonbyusingtheAUXswitch.
Thiscontrolleralsoincorporatesaturnsignaloverride.Wheneachoftheoverrideinputsfortheturnsignalis
wireddirectlytotherespectiveturnsignalcircuitofthevehicle,theappropriateendmoduleashesinsync
withtheturnsignalorhazardlights.Whenconnected,theturnsignalfeatureoverridesanyotherfunction
oftheModel331105,shuttingoffthedirectionallightbarduringtheturn,andreturningtothepreviously
activepatternwhentheturnsignaliscancelled.Theseinputsactivatewithaconnectiontopositive12Vdcto
24Vdc.Theyshouldbeleftdisconnectedwhennotneeded.
Whenstandarddirectionalsignaloperationisselected,thelampsilluminatesequentiallyinasweeping

Installation and Programming Instructions
3
Model 331105 SMC5 SignalMaster Controller
motionuntilallareilluminatedandthenrepeat.WhenTitle13Modeisselected,thelampsareextinguished
morequicklythaninstandardmode.Title13Modeprovidespatternsthatcomplywiththe40percentto60
percenton-time,andashrateof60FPMto120FPM,whicharerequirementsofCACTitle13,Article22.
WhenLOW(current)operationisselected,thelampsturnonthenoffinsequenceuntilapatternis
completed.WhenFASTisselected,thechosenpatternsequencesatanincreasedrate.
Althoughthecontrolleroperatesat12Vdcto24Vdc,ensurethattheSignalMasterlightbarisoftheproper
voltagefortheelectricalsystemofthevehicle.Donotoperatea12VSignalMasterat24Vora24V
SignalMasterat12V,orshortenedlamplifewillresult.
Model 331105 Controller Specifications
Electrical
Input Voltage: 11 Vdc to 28 Vdc
Polarity: Negative ground only
Operating Temperature Range: –30 °C to +65 °C
Standby Current: 7 mA (0.007 A)
Lightbar Fuse: 20 A, installer-provided; 40 A for two lightbars
+IGNITION Fuse: 2 A
Output Drive Capability (Total): Directional: Sixteen 27 W lamps on 8 channels
Auxiliary: Four 27 W lamps (two per output)
Two 55-watt lamps (1 per output)
Normal Directional Flash Rate: Approximately 30 patterns per minute
Fast Directional Rate: Approximately 45 patterns per minute
Dimensions
Height: 1-1/2 in
Width: 6-1/8 in
Depth: 5 in
Shipping Weight: 2.5 lb
Table 3 Parts list
Qty. Description Part No.
1 Controller 331105
1 Terminal Spade, Yellow, #10, 12–10 AWG 224297
1 Terminal Spade, Blue, #10, 16–14 AWG 224298
1 Mounting Bracket 8573070
2 Lockwasher, Ext. Tooth, 1/4"7075A007
2 Screw, Hex Head, 1/4"-20, Taptite 7011164-08

Installation and Programming Instructions
4Model 331105 SMC5 SignalMaster Controller
Installing the SignalMaster Lightbar
InstallthelightassemblyasdescribedintheinstructionsincludedwiththeSignalMaster.Routethecableto
the planned location of the controller.
Installing the Mounting Bracket for the Controller
Thesuppliedmountingbracketallowsthecontrollertobemountedinavarietyofpositions.Toinstallthe
mountingbracket:
CONTROLLER REQUIRES VENTILATION—This controller needs to radiate heat.
Do not install the unit in an area where it cannot dissipate heat into the air.
Do not mount the unit near a heater duct.
NOTE:Whenselectingamountinglocationforthecontrolunit,itisnecessarytokeepinmindthatsome
SignalMastermodelshavecableswhichare15-feetlong.Planwiringandcableroutingbeforeinstallation.
Nine-conductorextensioncablesareavailableifneeded.
1. Select a mounting location for the control unit that allows the vehicle and controls to be operated safely
at all times.
2. Usethemountingbracketasatemplateandscribetwodrill-positionmarksattheselectedmounting
location.SeeFigure1.
Figure 1 Bracket positions and hardware
290A5485B
BRACKET MAY BE REVERSED
AS SHOWN HERE TO MEET YOUR
MOUNTING REQUIREMENTS.
NOTE: ONLY ONE BRACKET
IS SUPPLIED.
1/4" LOCKWASHER,
EXT. TOOTH (2)
1/4-20 X 3/8" SCREW,
HEX WASH. HD (2)
SCREWS, THREAD FORM.,
USER SUPPLIED

Installation and Programming Instructions
5
Model 331105 SMC5 SignalMaster Controller
DRILLING PRECAUTIONS—When drilling holes, check the area into which you
are drilling to be sure that you do not damage vehicle components. All drilled
holes should be deburred and all sharp edges should be smoothed. All wire
routing going through drilled holes should be protected by a grommet or convo-
lute/split-loom weaving.
3. Drillaholesizedfortheinstaller-providedhardwaretobeusedinstep4ateachdrill-positionmark.
4. Securethemountingbrackettothemountingsurfacewithtwoinstaller-supplied,thread-forming,1/4"
screws or other hardware appropriate for the installation.
5. Beforefasteningthecontrollertothebracket,continuewiththeelectricalconnectionsasdescribedinthe
nextsections.
Connecting Power to the Controller
HIGH-CURRENT ARCING—Do not connect this system to the vehicle battery
until all other electrical connections are completed, and you have verified no
shorts exist. High-current shorts can cause hazardous sparks or burning wire
resulting in an electrical fire.
Thecontrollerisequippedwitha15-positionconnectorandtwoinsulatedspadeconnectors.Alsorequired
areinstaller-suppliedredandblackwiresofthepropergaugeforthecurrentandrunlengthofthespecic
installation.Fortherecommendedwiregauge,seeTable4.Thegroundwireshouldbesizedtohandlethe
total current used by the lightbar(s) and controller.
Table 4 Minimum wire gauge
Distance to
Battery
One SignalMaster
20 A Peak
Two SignalMasters
with a Shared Wire
20 A Peak
5 ft 18 AWG 16 AWG
10 ft 16 AWG 14 AWG
20 ft 12 AWG 10 AWG
30 ft 12 AWG 8 AWG
40 ft 10 AWG 8 AWG
If only one lightbar is to be connected, select a red wire of the appropriate gauge. If two lightbars are to be
installed,itisrecommendedthateachlightbarhasitsownfusedconnectiontothebattery.Twolightbarscan
sharethebatteryconnectionifthewireandfuseareappropriatelysized.
Installer-supplied18AWGredwireisrequiredfortheconnectionofthecontrollertothepositivepower
source.Installer-supplied18AWGwireisusedfortheoptionalAUXIN,RELAY,andTURNSIGNAL
OVERRIDEconnections.
Tomakethepowerconnectionstothecontroller:
1. Strip1/4"ofinsulationfromthemaingroundwireandcrimptheproperspadeconnectorontoit.

Installation and Programming Instructions
6Model 331105 SMC5 SignalMaster Controller
BATTERY EXPLOSION—To avoid a battery explosion, always disconnect the
negative battery cable first and reconnect it last. Avoid causing a spark when
connecting near or to the battery. The gases produced by a battery can cause a
battery explosion that could result in vehicle damage and serious injury.
CONNECTING THE RED AND BLACK WIRES—To avoid damage and ensure
proper operation, the red and black wires MUST be installed as shown in
Figure 3 on page 7.
2. ConnecttheblackgroundwiretothelugasshowninFigure3onpage7.Securelytightenthebinding
screwusinga1/4"at-tipscrewdriverpassingthroughtheopeninginthecover.
3. Routethegroundwirethroughtherewallandtowardthebattery.Connectittoagoodframeground
nearthebattery.Forgaugerecommendations,seeTable4.Inmostvehiclesawirefromthenegative
terminalofthebatteryisroutedandattachedtothescrewatthebody/frameatthefender.
4. Connecttheredwirefromthenine-conductorcableoftheSignalMastertothevehiclebatterythrougha
fuseholderthatislocatedasclosetothebatteryaspossible.Thefuseshouldbea20Atoprotectasingle
lightbarand40Aiftwolightbarsaretobeprotectedbyasinglefuse.Do not install the fuse until
all other electrical connections have been made.TorunbetweenthefusesandeachSignalMaster,
useaproperly-sizedredwire.IfasingleconductorwillbeusedtoprovidepowertotwoSignalMaster
lightbars, ensure that the wire is of the recommended gauge for the total load. For wire gauge
recommendations,seeTable4onpage5.
5. Selectaterminationpointforthe18AWGredpowerwirefromthecontroller.Asapplicable,route
the18AWGredwiretowardthevehiclefuseblockorthroughtherewalltowardthebattery.Ifthe
controllerpoweristobeconnectedtothebattery,useaninstaller-suppliedin-linefuseinthe18AWG
redwireasclosetothebatteryaspossibleandterminateitasrequired.Iftheredwireistobeterminated
tothefuseblock,andwillbeactiveonlywhenpoweredbytheignitionswitch,selectanappropriate
fused circuit.
IMPORTANT:Theterminationpointofthe18AWGredwirefromthecontrollerdetermineswhenthe
directionalsignalcanbeactivated.Whenthewireisattachedtoavehiclefusethatispoweredwhenthe
ignition switch is in the run or start position, the ignition switch must be in the run position to operate the
directionalsignal.Whenthewireisattachedtothevehiclebattery,thedirectionalsignalcanbeoperated
atanytime.Toavoiddrainingthebattery,FederalSignalrecommendsthatthepowerwirefromthe
controller be terminated to a switched source. NOTE:Thecontrollerdraws7mA(0.007A)intheoff
position when connected directly to the battery.
6. SeeFigures2and3onpage7.Strip1/4"ofinsulationfromallwiresthatyouplantoconnecttothe
15-positionterminalblockofthecontroller.Makealloftherequiredconnectionstotheterminalblockas
describedinthenextsection.
7. Connectthe18AWGredwiretothepositionlabeledontheterminalblockfor+12-24Vdc.

Installation and Programming Instructions
7
Model 331105 SMC5 SignalMaster Controller
Figure 2 Wire insertion into terminal block
290A5487B
TIP OF SMALL
SCREWDRIVER
STRIPPED
WIRES
1. INSERT SCREWDRIVER
TIP INTO RECTANGULAR
HOLE.
2. INSERT STRIPPED WIRE
END IN ROUND HOLE.
3. REMOVE SCREWDRIVER.
1/4"
WIRE STRIPPING
TYPICAL
Wiring the Six- and Eight-Head SignalMaster
TowiretheSignalMaster:
1. Connectthecoloredwiresfromthenine-conductorcabletothelocationsspeciedinFigure3oronthe
labelafxedtothecontrollerhousing.
Figure 3 Wiring from SignalMaster to controller
290A5486C
RIGHT TURN SIGNAL INPUT
LEFT TURN SIGNAL INPUT
AUX INPUT
RELAY
+ 12-24 Vdc SOURCE
RELAY:
CONNECT AS
NEEDED FOR
AUXILIARY
14 AWG
GROUND
CONNECTION
AUXILIARY CHANNEL 1
AUXILIARY CHANNEL 2
WHITE
BROWN
GREEN
ORANGE
VIOLET
GRAY
YELLOW
BLUE
MINIMUM 18 AWG
POWER WIRE FROM
CONTROLLER.
CONNECT TO
IGNITION OR BATTERY.
DRAWS 7 mA (0.007A)
AT BATTERY.
+BAT
20 A
RED POWER WIRE
FROM SIGNALMASTER
USE 14 AWG WIRE
FOR HOOKUP
9-CONDUCTOR
CABLE FROM
SIGNALMASTER
1 A
BINDING SCREW
FOR GROUND WIRE
2 A FUSE

Installation and Programming Instructions
8Model 331105 SMC5 SignalMaster Controller
NOTE:Withthesix-headSignalMasterlightbar,thewhiteandbluewiresarenotneededandcanbecut
even with the cable sheath.
2. ForsplitSignalMasterswherethree-orfour-headassembliesmakeupafullsix-oreight-head
SignalMasterassembly,connectthewirestotheterminalblocksinorderfromlefttoright.Theoutput
labeledBLUEonthecontrollerisfortherightmostlamp,andtheonelabeledWHITEisfortheleftmost
lamp.Foranexampleoftheconnectionoftwofour-headSignalMasterstothecontroller,seeFigure4.
3. Whenallelectricalconnectionsarecompleted,inserta20AfuseintothefuseholderintheSignalMasterred
power wire.
4. Connectanyoptionalauxiliarywarningheadstotheauxiliarycircuits.Thecontrollerwillprovide
agroundfortheheadswhentheyaretoash.Therefore,thepositivesideoftheheadsshouldbe
connected to a positive voltage source and protected with a fuse.
Figure 4 Connections for two four-head SignalMasters to the controller
BROWN
FIVE-CONDUCTOR
CABLE FROM RIGHT
SIGNALMASTER
20 A
+ BAT
JOIN THE RED POWER
WIRES FROM
SIGNALMASTERS.
USE 14 AWG WIRE
FOR HOOKUP.
FIVE-CONDUCTOR
CABLE FROM LEFT
SIGNALMASTER
BROWN
GREEN
WHITE
BROWN
GREEN
WHITE
BLACK
GREEN
ORANGE
VIOLET
GRAY
YELLOW
BLUE
WHITE
COLORS
INDICATED ON
SMC LABEL
COLORS OF
FIVE-CONDUCTOR
CABLE
BLACK
290A5694B
5. TheAUXINcanbeusedasaninputtoactivatethewarningpatternwhenanexternalinputisavailable
provided that a directional signal is not currently activated by the slide switch.
 Whentheslideswitchisactivated,itoverridestheauxiliaryinput(warningsignal)andprovidesthe
selected directional signal instead.
 Whentheslideswitchisreturnedtotheoffposition,thewarningpatternresumesifthesignalatthe
auxiliaryinputisstillactive.Connecttheexternalcontrollerinamannertoapplyapositive12-24Vdc
orground.Thisparticularinputcanbeswitchedwitheitherhigh-sideorlow-sideactivationprovided
that the off state is an open circuit.

Installation and Programming Instructions
9
Model 331105 SMC5 SignalMaster Controller
UNINTENDED DIRECTIONAL SIGNAL—Certain combinations of auxiliary and
warn patterns may produce an unintended directional signal, particularly when
the auxiliary heads are inline with the SignalMaster. Operate the selected warn
and auxiliary patterns simultaneously and verify that no pseudo-directional
pattern is produced over a period of several minutes. Failure to heed this
warning could confuse drivers, causing serious injury or death.
6. TheAUXbuttoncanbeusedtopoweraninstaller-suppliedrelaythatactivatesothercircuitswhentheAUX
functionisselected.Therelayconnectionprovidesagroundtoactivatetherelay(Figure3onpage7).
a. Selectarelaywitharatedcapacitysufcientfortheloadtobeswitched.
b. Connectonelegoftherelaycoiltopositive12-24Vdc.Usea1Afusetoprotectthecircuit.
c. ConnecttheremaininglegoftherelaycoiltotheterminalmarkedRELAY.WhentheAUXbuttonis
pressed the terminal becomes a ground to activate the relay.
Connecting the Turn Signal Override
Thecontrollercanbeconnectedsothatasingleendmoduleashesinsyncwiththevehicleturnsignal.
Ifanypatternisdisplayedwhentheturnsignalsareashing,thepatternissuspendedandthesinglehead
beginstoash.Whentheturnsignalisreturnedtotheoffposition,thesuspendedpatternre-activates
afterapproximatelyonesecond.Eachturnsignalinputattherearofthecontrollermustbetappedintoits
respectiveturnsignalcircuitforoverridetowork.Whentheturnsignaloverrideisconnected,turningonthe
vehiclehazardlightswillactivatebothleftandrightheads.
Tomaketheconnections:
1. Runa18AWGwirefromtheinputfortherightturnsignaltoasuitablepointonthecircuitfortheright
turn signal.
2. Connecttheleftturninputintotheleftturnsignalcircuit.Consultthevehiclewiringdiagramtondthe
appropriate connection points.
Mounting the Controller
Tofastenthecontrollertothebracket:
1. Placethecontrollerintothemountingbracket(Figure1onpage4).
2. Fasten the controller using the two self tapping screws provided.
3. Anglethecontrollerforoptimumvisibilityfromtheoperator’spositionbeforetighteningthescrews.
4. Dressthecablesandwires,andsecurethemoutoftheway.

Installation and Programming Instructions
10 Model 331105 SMC5 SignalMaster Controller
Configuring the Controller
Thecontrollerhasseveralinstaller-selectableoptionsthatyoucanselectinProgrammingModeafterthe
installationandwiringoftheSignalMastersystemiscomplete.Seethenextsectionforprogramming
instructions.Forthefunctionsofthecontrollerbuttons,seeFigure5belowand“OperatingtheSignalMaster
Controller”onpage13.
Figure 5 Model 331105 SMC5 controller
290A5488B
FOUR-POSITION
SLIDE SWITCH
AUXILLIARY HEAD LED INDICATORS
SIGNALMASTER
LED INDICATORS
Table 5 Standard warn patterns
Pattern
No. Description
0 Null (no pattern)
1 Center light alternate with lights at each end
2 The lights alternate on each half of the lightbar
3 Alternating pairs
4 Two-head groups, center out
5 Moving triple flash
6 Ripple with emphasis at end
7 Jumping pairs
8 Alternating odds and evens
9 Quad flash with full lightbar accent
10 Random 1, single heads
11 Random 2, moving gap
12 Ripple out, fast
13 Alternating pairs, fast