Federal Signal Corporation Signalmaster 330103 User manual

2561006D
REV. D 502
Printed in U.S.A
.
INSTRUCTION SHEET
FOR
SIGNALMASTER™ MODEL 330103
SAFETY MESSAGE TO INSTALLERS
People’s lives depend on your safe installation of our products.
It is important to read, understand and follow all instructions
shipped with the products. In addition, listed below are some other
important safety instructions and precautions you should follow:
• To properly install this light: you must have a good
understanding of automotive electrical procedures
and systems, 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.
• 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 light 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 CON-
TROL 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 LED 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 to you or
others.
I. GENERAL.
The Federal Signal SignalMaster Model 330103 is an
economical, low profile, solid state, directional light control that is
designed to operate with any of Federal Signal’s SignalMaster
series eight-lamp directional lights. This control will also operate
two sets of external lamps (Federal Signal Models 320102,
SMLED1, 320112, and 320721, or other 50 watt lamps). The unit
is reversed polarity protected to avoid damage if the positive and
negative power connections are connected incorrectly.
This model provides three distinctive directional signals, left
arrow, right arrow, and center out. An alternating flash pattern
produces a warning signal for use when a directional signal may
not be appropriate. In addition, an auxiliary flash pattern
alternately flashes the external lamps. When a directional signal
is selected, the lamps individually activate sequentially in a
sweeping motion until all eight are illuminated. The slide switch
overrides the WARN and AUX functions
An auxiliary input and output are provided for integrating
external controls and lights into the SignalMaster system. When
properly connected, a positive (+)12 volts applied to the AUX IN
terminal will activate the alternating flash pattern. The AUX OUT
terminal can activate a ground-activated relay ( user-supplied)
when the AUX switch is operated.
WARNING
These lights are intended for secondary warning only.
They are not intended for use as a primary warning
system.
II. SPECIFICATIONS.
Input Voltage 11VDC to 16VDC.
Polarity Negative ground only.
Operating Temperature -30°C to +65°C.
Range
Standby Current Zero amperes.
+BAT Fuse 25 amperes.
+IGN/BAT Fuse 1 ampere.
AUX OUT Fuse 1 ampere.
Output Drive
Capability (Total)
Directional 8, 27 watt lamps.
Auxiliary 4, 27 watt lamps (2 per output) or
2, 50 watt lamps (1 per output).
Flash Rate:
Directional 35 patterns/min.
Warn 60 patterns/min.
Dimensions:
Height 1-1/2"
Width 6-1/8"
Depth 5"
Shipping Weight 2.0 lbs.
III. INSTALLATION.
WARNING
When installing equipment inside air bag equipped ve-
hicles, the installer MUST ensure that the equipment is
installed ONLY in areas recommended by the vehicle
manufacturer.
Failure to observe this warning will reduce the effective-
ness of the air bag, damage the air bag, or potentially
damage or dislodge the equipment, causing serious injury
or death to you or others.
A. SignalMaster Light Assembly.
Install the light assembly as described in the instruc-
tions packed with the 320340 universal mounting kit. Route the
cable near the eventual location of the control unit.
B. Control Unit.
See figure 1. The supplied mounting bracket allows the
control unit to be mounted in a variety of positions. To install the
control unit, proceed as follows:

Figure 1.
CAUTION
Install the control unit in an adequately ventilated area.
Never install near heater ducts.
NOTE
When selecting a mounting location for the control unit,
it is necessary to keep in mind the SignalMaster
cable length. Plan wiring and cable routing before
installation.
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.
CAUTION
Before drilling holes in ANY part of a vehicle, be sure that
both sides of the mounting surface are clear of parts that
could be damaged; such as brake lines, fuel lines, electrical
wiring or other vital parts.
3. Drill two holes at the previously scribed position
marks.
4. Secure the mounting bracket to the mounting
surface with two user-supplied, thread-forming, 1/4-20 screws.
C. Electrical Connections.
WARNING
Failure to observe this WARNING may result in fire,
burns or blindness.
If shorted to vehicle frame, high current conductors can
cause hazardous sparks resulting in electrical fires or
molten metal.
DO NOT connect this system to vehicle battery until ALL
other electrical connections are made and mounting of all
components is complete.
Verify that no short circuits exist, before connecting to the
Positive (+) battery terminal.
Figure 2.
The control unit is supplied with a six-position connector
and a eleven-position connector to perform the electrical installa-
tion. User-supplied, 14-gauge red and black wires are required for
the (+) BAT and (-) GND connections on the six-position connector.
User-supplied, 18-gauge red and green wires are required for the
(+) BAT/IGN and CASE GROUND connections on the six-position
connector. In addition, user-supplied 18-gauge wire is used for the
AUX IN and AUX OUT connections. Using figure 2 as a guide,
complete this portion of the installation as follows:
1. Power Connections.
CAUTION
To avoid damage and ensure proper operation, the red
and black wires MUST be installed in the six-position
connector as shown in figure 3.
a. Strip 1/4" of insulation off of each wire. See
figure 3. Use small blade screwdriver to depress spring in
connector, insert proper wire and remove screwdriver to release
spring.
b. Connect the red and black 14-gauge wires to
the connector as shown in figure 3.
c. Route the red and black 14-gauge wires
through the firewall and toward the battery. Connect the black
wire to a good frame ground near the battery. In most vehicles, a
wire from the negative terminal of the battery is routed and
attached to the body/frame at the fender. This is a convenient
point to connect the 14-gauge black wire. Do not connect the red
wire to the (+) positive terminal at this time.
d. Connect the 18-gauge red and green wires to
the connector as shown in figure 3.
IMPORTANT
The 18-gauge red wire’s termination point 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 vehicle’s
ignition switch must be in the run or start position to
operate the directional signal. When the wire is attached
to the vehicle battery, the directional signal can be oper-
ated at any time. Note that the unit draws no current
when in the “off” position.
e. Select the desired termination point. As
applicable, route the 18-gauge red wire toward the vehicle fuse
-2-
+BAT
24 AMP.
+BAT/IGN
(-) GND
(-) CASE
GROUNG
AUX IN
AUX OUT
WHITE
BROWN
GREEN
ORANGE
VIOLET
GRAY
YELLOW
BLUE
WHT/BLU
WHT/GRN
WHT/RED
WHT/ORN
RED
CUSTOMER SUPPLIED
320162 & 320752
BRN
WHT
GRN
BLUE
YEL
GRAY
PRP
ORN
290A2542-49C
9 CONDUCTOR
CABLE FROM
SIGNALMASTER
18 AWG AUX OUT
18 AWG AUX IN
18 AWG CASE GND.
14 AWG (-)GND
18 AWG +BAT/IGN.
14 AWG +BAT
LIGHT OUTPUTS
POWER AND
GROUND
25A 1A
1A
1/4"
WIRE STRIPPING
TYPICAL
RED
EXTERNAL LAMP
CONNECTIONS
330103
290A2542-47
B
WARN
AUX
BRACKET MAY BE
REVERSED AS SHOWN HERE,
IF IT BETTER SUITSYOUR SPECIFIC
MOUNTING REQUIREMENTS.
NOTE: ONLY ONE BRACKET IS SUPPLIED.
1/4-20 x 3/8" SCREW,
HEX WASH. HD.(2)
1/4" LOCKWASHER,
EXT.TOOTH(2)
SCREWS,THREAD FORM.,
USER SUPPLIED
330103

block or through the firewall toward the battery. Install a user-
supplied, 1-ampere, in-line fuse in the 18-gauge red wire as close
to the power source as possible and terminate as required.
f. Route the 18-gauge green wire to a known good
chassis ground near the 330103 control. To provide a good ground
connection, scrape any painted surface to bare metal.
2. AUX IN and AUX OUT Connections.
When a positive (+)12 volts is applied to the AUX IN
connection, the alternating flash pattern is activated. The AUX
OUT connection will provide a ground to activate a ground-
activated relay ( user-supplied) when the AUX switch is operated.
To perform the wiring for these connections, proceed as follows
(see figures 2 and 3):
CAUTION
To avoid damage and ensure proper operation, the wires
MUST be installed in the six- position connector as shown
in figure 3.
a. Connect a user-supplied 18-gauge wire to the
six-position connector’s AUX IN connection. Route the wire to a
user-supplied external switch which will provide a positive (+) 12-
volts (such as Federal Signal Model SW400SS) when activated.
b. Connect a user-supplied 18-gauge wire to the
six-position connector’s AUX OUT connection. Route the wire to a
user-supplied ground-activated relay for activation of an external
device. Install a user-supplied, 1-ampere, in-line fuse between the
control and the relay.
3. SignalMaster Cable Connections.
a. Route the SignalMaster cable towards the
control unit, while being careful not to scrape the wires on any
sharp edges.
b. If necessary, cut the cable to the appropriate
length.
c. Connect the 18-gauge wires and 16-gauge red
wire to the eleven-position connector as shown in figures 2 and 3.
Positions 9 and 10 are used for external lamp connections. Each of
these two positions provides an alternating ground signal to
activate external lamps.
D. Inspection and Final Installation.
1. Ensure that there are no loose wire strands or other
bare wires which may cause a short circuit. Also, all wires must be
protected from any sharp edges which could eventually cut
through the insulation.
2. Plug the six-position connector into the mating
connector on the control unit, and apply pressure until it locks into
place.
3. Plug the eleven-position connector into the mating
connector on the control unit, and apply pressure until it locks into
place.
4. Connect the remaining end of the 14-gauge red wire
from the six-position connector to the (+) positive terminal of the
battery using an in-line, user-supplied, fuseholder and 25A fuse.
Locate the fuse as near the battery as possible to protect the entire
length of wire.
5. Read and understand paragraph IV OPERATION,
and test for proper operation of all functions.
6. Secure the mounting bracket to the control unit
with the 1/4-20 hex head, thread forming screws and 1/4" external
tooth lock washers (see figure 1).
IV. OPERATION.
SAFETY MESSAGE TO OPERATORS
Peoples’ 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 controls high intensity LED devices. To
prevent 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 all lamps are operat-
ing properly. The LED display on the control only
simulates the operation of the lamps.
• 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.
Failure to follow these safety precautions may result in
property damage, serious injury, or death to you, to passengers, or
to others.
RETAIN AND REFER TO THIS MESSAGE
See figure 4. All controls utilized during normal operation of
the SignalMaster directional light are located on the front panel of
the control unit. The LED display simulates the light pattern
being executed by the directional light.
-3-
Figure 3.
Figure 4.
290A2542-45B
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
OFF WARN
AUX
290A2542-39
B
330103
FEDERAL SIGNAL CORPORATION
SignalMaster
TM

A. Slide Switch.
1. LEFT (Position 1).
In this position, the light produces a left arrow
flashing pattern, instructing traffic to move left.
2. CENTER OUT (Position 2).
In this position, a center out flashing pattern is
produced, instructing traffic to move around either side of the
vehicle.
3. RIGHT (Position 3).
In this position, the light produces a right arrow
flashing pattern, instructing traffic to move right.
B. WARN switch.
When this switch is pressed, an alternating pattern is
produced. The four middle lights activate alternately with the two
outside lights on each side. The slide switch will override this
pattern.
C. AUX switch.
1. When this switch is pressed, external lamps
alternately flash at a constant rate. The wiring configuration
determines the flash combination of the external lamps. The slide
switch will override the external lamp pattern when the AUX
switch is depressed, but will not override the AUX OUT terminal
output.
2. If connected, the six-position connector’s AUX OUT
connection provides a ground to activate a user-supplied relay to
control an external device.
D. Auxiliary Input.
If connected, application of a positive (+) 12-volts to the
AUX IN connection on the six-position connector produces the
WARN pattern described above. When the positive (+) 12-volts is
removed from the AUX IN connection, the WARN pattern will
stop. Slide switch activation will override the WARN pattern.
V. SERVICE.
A. General.
Servicing, other than cosmetic features, should be
performed by a qualified Federal Signal service center. If the
control unit is not working properly, disconnect all electrical
connections starting with the six-position power connector.
Remove the control unit from the mounting bracket. Send the unit
to the nearest authorized service center or the Federal Signal
service department.
Communication and shipments should be addressed to:
Service Department
Federal Signal Corporation
2645 Federal Signal Drive
University Park, IL 60466
1-800-433-9132
After servicing is complete, perform a test of all
functions to ensure the control unit is operating properly.
B. Replacement Parts List.
Description Part Number
Printed Circuit Board Assembly 2001136-01
Knob, Pushbutton 8573065
Knob, Slide Switch 8536C1041
Bezel, Slide Switch 8573060
Connector, Female, 6-position 140325-04
Connector, Female, 11-position 140325-09
Bracket, Mounting 8573070
Screw, Hex Head, Mounting 7011164-08
Lockwasher, 1/4" 7075078
Chassis 8573068
Cover 8573066
-4-