Federal Signal Corporation Integrity Series Manual

25500063
REV. B2 0820
© Copyright 2014-2020 Federal Signal Corporation
Installation, Maintenance,
and Service Manual
Integrity Light Bar

blank page
Limited Warranty
This product is subject to and covered by a limited warranty, a copy of which can be found at
www.fedsig.com/SSG-Warranty. A copy of this limited warranty can also be obtained by written request to Federal
Signal Corporation, 2645 Federal Signal Drive, University Park, IL 60484, email to [email protected] or call
[phone].
This limited warranty is in lieu of all other warranties, express or implied, contractual or statutory, including, but
not limited to the warranty of merchantability, warranty of fitness for a particular purpose and any warranty against
failure of its essential purpose.
2645 Federal Signal Drive
University Park, Illinois 60484-3167
www.fedsig.com
Customer Support
Police/Fire-EMS: 800-264-3578 • [phone]
Work Truck: 800-824-0254 • [phone]
Technical Support 800-433-9132 • [phone]

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Installation, Maintenance, and Service Manual
Federal Signal www.fedsig.com
Contents
Safety Messages.............................................................................................................................. 6
Safety Message to Installers and Service Personnel of Warning Lights...........................................6
Safety Messages to Operators of Federal Signal Sound/Light Systems ..........................................9
An Overview of the Integrity®Light Bar ...................................................................................... 10
LED Lights, Colors, and Flash Patterns.................................................................................................... 10
Electrical System............................................................................................................................................10
Controller Options .........................................................................................................................................10
Ambient Light Sensor/AutoDim Option ...................................................................................................10
Product Specifications................................................................................................................................... 11
Reprogramming the Light Bar...................................................................................................... 12
Reprogramming the Light Bar .................................................................................................................... 12
SignalMaster Operation: Internal (Factory Default) or External ................................................... 12
MODE 1, 2, 3, and INTERSECTION ..................................................................................................... 12
FRONT and REAR lights: CUTOFF (default) or ENABLE ................................................................ 12
Making the Electrical Connections for Reprogramming................................................................ 12
Switch Settings and Connectors on the Serial Interface Module ............................................... 13
Selecting External SignalMaster Control ........................................................................................... 14
Selecting Internal SignalMaster Control (Factory Default)............................................................ 15
Identifying the Control Wires for Flash Patterns.............................................................................. 15
Entering Program Mode......................................................................................................................... 16
Exiting Program Mode ............................................................................................................................ 18
Wiring the Integrity Light Bar in the Vehicle .............................................................................. 19
Planning the Electrical Installation............................................................................................................. 19
Connecting Power to the Light Bar .........................................................................................................20
Installing the Serial Interface Module....................................................................................................... 21
Wiring the Serial Interface Module........................................................................................................... 23
Priority Modes 1, 2, and 3...................................................................................................................... 23
Steady Burn .............................................................................................................................................. 23
Front Cuto............................................................................................................................................... 23
Rear Cuto................................................................................................................................................ 23
Intersection............................................................................................................................................... 24
Flash Takedown/Alley............................................................................................................................ 24
Left and Right Alley Lights.................................................................................................................... 24
Takedown Lights ..................................................................................................................................... 24
Scene Light, Left and Scene Light, Right.......................................................................................... 24

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Federal Signal www.fedsig.com
Figures
Figure 1 Electrical connections for reprogramming the light bar..................................................... 13
Figure 2 DIP switch settings in Serial Interface Module..................................................................... 14
Figure 3 Power and cable connections.................................................................................................. 21
Figure 4 Relay for isolating devices with large filter capacitors......................................................22
Figure 5 SignalMaster 331105 controller (external SignalMaster control) ....................................26
Figure 6 SmartSiren SS2000SM Series controller (external SignalMaster control) ..................26
Figure 7 SignalMaster control functions wired to ground for external SIM control ................... 27
Figure 8 SignalMaster control functions wired to 12 Vdc for Internal control..............................29
Figure 9 Typical connections with a SignalMaster controller (external control) ......................... 30
Figure 10 Typical connections with a Model SW400SS Switch Module (internal control) ......... 31
Figure 11 Typical connections with a SmartSiren Model SS2000SM controller.......................... 32
Figure 12 Typical connections with a non-SignalMaster controller................................................ 33
Figure 13 Typical connections with a Model PA640 (PA64000) controller .................................. 34
Figure 14 Locations of ROC PCBs ........................................................................................................... 35
Figure 15 Locations of the barrel nuts in lens (numbers indicate tightening sequence).......... 37
Figure 16 Locations of ROC PCBs ........................................................................................................... 38
Low Power or Optional AutoDim ........................................................................................................ 24
Ignition .......................................................................................................................................................25
SignalMaster Connections....................................................................................................................25
Maintaining and Servicing the Integrity ...................................................................................... 35
Installing the Filler Strips (Sponge Cords) .............................................................................................. 35
Cleaning the Light Bar Lens....................................................................................................................... 36
Removing and Reinstalling the Light Bar Lens...................................................................................... 36
Removing the Lens................................................................................................................................. 36
Reinstalling the Lens .............................................................................................................................. 37
Replacing a PCB............................................................................................................................................ 37
Removing a PCB...................................................................................................................................... 38
Reinstalling a ROC PCB......................................................................................................................... 38
Resetting the Controller .............................................................................................................................. 39
Troubleshooting the Light Bar................................................................................................................... 40
Getting Technical Support and Service....................................................................................... 42
Getting Repair Service................................................................................................................................. 42
Ordering Replacement Parts ..................................................................................................................... 43

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Tables
Table 1 Dimensions....................................................................................................................................... 11
Table 2 Light Specifications....................................................................................................................... 11
Table 3 Electrical and Temperature ......................................................................................................... 11
Table 4 SW-2 DIP Switch Settings........................................................................................................... 14
Table 5 Control wires from the Serial Interface Module ................................................................... 15
Table 6 Switch settings for INTERSECTION operation...................................................................... 18
Table 7 Cross reference for controller leads (external Serial Interface Module control)......... 26
Table 8 SignalMaster control wires and warning patterns (internal SM control)) ..................... 27
Table 9 Troubleshooting tips................................................................................................................... 40
Table 10 Replacement parts..................................................................................................................... 43

Safety Messages
6Integrity Light Bar
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Safety Messages
For your safety, read and understand this manual thoroughly before installing, operating,
and servicing the Integrity®light bar. The safety messages presented in this section
and throughout the manual are reminders to exercise extreme care at all times. Read
and understand the safety instructions and keep them close at hand for reference. To
download copies of this manual, go to www.fedsig.com or call the Federal Signal Service
Department at 1-800-433-9132, 7  to 5 , Monday through Friday (CT).
Safety Message to Installers and Service Personnel of Warning Lights
Before Installation or Service
Qualifications
• To properly install or service this equipment, you must have a good understanding of
automotive mechanical and electrical procedures and systems, along with proficiency
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
• In order to be an eective 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 field 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 dierent manufacturers
may reduce the warning eectiveness of the lighting system and may damage the
components. Verify or test your combination to make sure 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 o. After disconnecting power to the unit, wait five 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.

Safety Messages
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Installation, Maintenance, and Service Manual
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• 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 aect vehicle operation or mandated safety
functions or circuits. Always check the vehicle for proper operation after installation.
• The lighting system components, especially light bulbs, strobe tubes, LEDs, and the
outer housing, get hot during operation. 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 flying glass. Always wear gloves and eye protection when handling these
components.
• Do not mount a radio antenna within 18 inches 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 fields. 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 this or any other electrical device while it is connected to its
power source. Exposure to liquid while the product is connected to the power source
may result in an electrical shock and personal injury and may short circuit and damage
the product.
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 ensure there are no shavings
present in or near the unit.
• 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.
• 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 verified
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 fires or flying molten
metal.
• DO NOT install equipment or route wiring (or the plug in cord) 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.
• Before mounting any components, check the manual to verify 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.

Safety Messages
8Integrity Light Bar
Federal Signal www.fedsig.com
• The 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, ensure 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.
Ensure that the mounting screws do not cause electrical or mechanical damage to
the vehicle.
• To avoid denting the roof of the vehicle, place the light bar mounting feet as close
to outer edge of the roof as possible.
• Roof damage can occur if the hook adjustment bolts are over-tightened. Torque
the adjustment bolts to 6 ft-lb to 7 ft-lb. Install keeper plates.
• 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.
• If a seat is temporarily removed, verify with the vehicle manufacturer if the seat
needs to be recalibrated for proper airbag deployment.
• Test all vehicle functions, including horn operation, vehicle safety functions, and
vehicle light systems, to ensure proper operation. Ensure that the installation has
not aected the vehicle operation or changed any vehicle safety function or circuit.
• Scratched or dull reflectors, mirrors, or lenses will reduce the eectiveness 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 deactivate the light system control while driving in a
hazardous situation.
• 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 sta and all operating personnel.
• Do not use a pressure washer to clean the light bar. Failure to heed this notice will
damage the light bar.
• 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.

Safety Messages
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Installation, Maintenance, and Service Manual
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Safety Messages to Operators of Federal Signal Sound/Light Systems
People’s lives depend on your safe operation of Federal Signal products. It is important
to read and follow all instructions shipped with the products. Listed below are some other
important safety instructions and precautions you should follow:
• Do not attempt to activate or deactivate the light system control while driving in a
hazardous situation.
• Although your warning system is operating properly, it may not be completely
eective. People may not see or heed your warning signal. You must recognize this
fact and continue to drive cautiously.
• Situations may occur that 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.
• All eective sirens and horns produce loud sounds that may cause, in certain
situations, permanent hearing loss. You and your passengers should consider taking
appropriate safety precautions, such as wearing hearing protection.
• The eectiveness of an interior mounted warning light depends on the clarity, the
tinting, and the angle of the glass it is being placed behind. Tinting, dirt defects, and
steeply angled glass reduce the light output of the warning light. This may reduce the
eectiveness of the light as a warning signal. If your vehicle has dirty, tinted, or steeply
angled glass, use extra caution when driving your vehicle or blocking the right of way
with your vehicle.
• To be an eective 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.
• Operate your vehicle and the 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 o, disconnect the power connector from the control unit and
contact the nearest service center.
• At the start of your shift, ensure that the entire warning light system and the siren
system is securely attached and operating properly.
Failure to follow all safety precautions and instructions may result in property damage,
serious injury, or death.

An Overview of the Integrity® Light Bar
10 Integrity Light Bar
Federal Signal www.fedsig.com
An Overview of the Integrity®Light Bar
The Integrity light bar is a single-level LED light bar with ROCTM (Reliable On-Board
Circuitry) and Solaris®LED technologies. ROC eliminates approximately 85 percent of
potential failure points by incorporating a printed circuit board (PCB) in one assembly
to substantially reduce the number of electrical connections. Solaris S2 LED modules
use oset, complex reflector surfaces for accurate beam-shaping and the highest
optical eciency. The reflectors’ overlapping, 360-degree lighting eliminates weak
spots and provides o-axis warning around the light bar.
LED Lights, Colors, and Flash Patterns
The microprocessor inside the light bar supplies three priority operational modes and a
library of 27 flash patterns. To increase the safety of ocers, pedestrians, and motorists,
the light bar has standard front and rear cuto, dimming, and intersection warning. Bright
white LED takedown and alley lights that are horizontally adjustable are also available
with the HotFoot™configured option.
Multi-color heads are available with up to three dierent colored LEDs, eliminating the
loss of primary warning colors in takedown, alley, and directional warning positions.
Individual Integrity light heads can flash between red, blue, amber, or white.
Electrical System
The Integrity light bar is protected against reversed polarity damage. The Integrity
Light Bar can be installed in any vehicle with a 12-volt negative-ground electrical
system.
Controller Options
Flash patterns are controlled through the light bar CAT5 communication cable.
The cable connects to Federal Signal Convergence network controllers, the Serial
Interface Module (Part Number 8583446), or the Federal Signal Six-Button Serial
Controller.
With the Serial Interface Module, the Integrity Light Bar can be activated by Federal
Signal light bar controllers, SignalMaster directional-light controllers, or by individual
low-current switch boxes.
Ambient Light Sensor/AutoDim Option
The Integrity light bar can be ordered with an optional ambient light sensor. The sensors
that detect the ambient light and automatically dim flashing lights during nighttime are
located on the ROC boards at each end of the light bar. If used with a controller that has
a dedicated dim button, the user has the option to temporarily override the dimming.
AutoDim is disabled in MODE 3 and is enabled when MODE 3 is removed.
Other advanced features of the Integrity light bar include:
• A high degree of reliability through the use of advanced microprocessors and other
integrated circuits.
• One-piece seamless construction that eliminates leaking bulkhead gaskets.
• High output, long-life LEDs with no bulbs to change.