Federal Signal Corporation Valor VALR44 Manual

2562549
REV. C3 0820
Printed in U.S.A.
© Copyright 2015-2020 Federal Signal Corporation
Installation, Maintenance,
and Service Manual
Valor®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 tness 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]
All product names or trademarks are properties of their respective owners.

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Installation, Maintenance, and Service Manual
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Contents
Safety Messages.............................................................................................................................. 5
Safety Message to Installers and Service Personnel of Warning Lights...........................................5
Safety Message to Operators of Warning Light Equipment.................................................................8
An Overview of the Valor Light Bar ............................................................................................. 10
LED Lights, Colors, and Flash Patterns.................................................................................................... 10
Modular Connector System ........................................................................................................................10
Controller Options .........................................................................................................................................10
Preparing the Valor for Installation.............................................................................................. 12
Unpacking the Light Bar .............................................................................................................................. 12
Connecting the Valor for Programming................................................................................................... 12
Selecting External SignalMaster Control................................................................................................. 14
Selecting Internal SignalMaster Control (Factory Default).................................................................. 14
Entering Program Mode............................................................................................................................... 15
Exiting Program Mode.................................................................................................................................. 19
Wiring the Valor in the Vehicle .................................................................................................... 20
Planning the Electrical Installation............................................................................................................20
Connecting Power to the Light Bar .......................................................................................................... 21
Installing the Serial Interface Module......................................................................................................22
Wiring the Serial Interface Module........................................................................................................... 24
Maintaining and Servicing the Valor............................................................................................ 35
Cleaning the Light Bar Lens....................................................................................................................... 35
Removing and Reinstalling the Light Bar Lens...................................................................................... 36
Replacing a PCB............................................................................................................................................ 37
Disconnecting/Connecting Power and CAT5 at the Light Bar ......................................................... 38
Troubleshooting the Light Bar.................................................................................................................... 41
Quick Testing the Valor with the Light Bar Test.................................................................................... 42
Testing the Steady Burn LEDs (HotFoot Only) ...................................................................................... 43
Getting Technical Support and Service....................................................................................... 43
Getting Repair Service................................................................................................................................. 43
Replacement Parts........................................................................................................................................ 44

4Valor®Light Bar
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Figures
Figure 1 Serial Interface Module connections for programming ........................................................... 13
Figure 2 Connectors and switches on the Serial Interface Module ..................................................... 17
Figure 3 Relay-isolating devices with large filter capacitors ................................................................. 23
Figure 4 Wiring block diagram ...................................................................................................................... 24
Figure 5 SignalMaster flash sequences...................................................................................................... 27
Figure 6 SignalMaster control functions wired to 12 Vdc for internal SIM control........................... 28
Figure 7 SignalMaster control functions wired to ground for external SIM control......................... 29
Figure 8 Typical connections with a SignalMaster controller (external control)............................... 30
Figure 9 Typical connections with a SW400SS Switch Module (internal control) ............................ 31
Figure 10 Typical connections with a SmartSiren Model SS2000SM controller.............................. 32
Figure 11 Typical connections with a non-SignalMaster controller....................................................... 33
Figure 12 Typical connections with a PA640 controller.......................................................................... 34
Figure 13 Locations of barrel nuts in light bar cover................................................................................ 36
Figure 14 Location of controller..................................................................................................................... 37
Figure 15 Locations of watertight connectors ........................................................................................... 38
Figure 16 Secondary lock mechanism in the plug and receptacle...................................................... 39
Tables
Table 1 Dimensions ............................................................................................................................................ 11
Table 2 Light Specifications ............................................................................................................................ 11
Table 3 Electrical and Temperature............................................................................................................... 11
Table 4 SW2 DIP switch settings in the Serial Interface Module.......................................................... 15
Table 5 Control wires from the Serial Interface Module......................................................................... 16
Table 6 Switch settings for Intersection operation .................................................................................. 19
Table 7 SignalMaster control wires and warning patterns ................................................................... 27
Table 8 Troubleshooting tips ......................................................................................................................... 41

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Installation, Maintenance, and Service Manual
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Safety Messages
Safety Messages
For your safety, read and understand this manual thoroughly before installing,
operating, and servicing the Valor light bar. The safety messages presented in this
chapter and throughout the manual are reminders to exercise extreme care at all
times. To download copies of the manual, go to www.fedsig.com or call the Federal
Signal Service Department at 1-800-433-9132, 7 a.m. to 5 p.m., Monday through Friday
(CT).
Safety Message to Installers and Service Personnel of Warning Lights
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.
Listed below are some other important safety instructions and precautions you should
follow:
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 service manuals when performing equipment installations on a
vehicle.
Light Hazards
• 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 safely operate the vehicle.
• Federal Signal power supplies and lightheads are designed to work together as
a system. Combining lightheads and a power supply from dierent manufacturers
may reduce the warning eectiveness 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 o. After disconnecting power to the unit, wait five minutes
before handling any parts of the strobe system.

6Valor®Light Bar
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Safety Messages
• 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 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. 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 flying 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 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 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.
• 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 caused 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.

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Installation, Maintenance, and Service Manual
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Safety Messages
• 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 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.
• 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, 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 fly
o 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 light bar mounting feet as close
to the outer edge of the roof as possible.
• Roof damage can occur if the hook adjustment bolts are over-tightened. On Arjent
and Vista light bars tighten the hook-adjustment bolts 10 ft-lb to 11ft-lb. On all
other light bars tighten the adjustment bolts 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.
• To ensure proper operation, test all vehicle functions, including horn operation,
vehicle safety functions, and vehicle light systems. Ensure that the installation
has not aected the vehicle operation or changed any vehicle safety function or
circuit.

8Valor®Light Bar
Federal Signal www.fedsig.com
Safety Messages
• 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 de-activate 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.
• File these instructions in a safe place and refer to them when maintaining and/or re-
installing the product.
Failure to follow these precautions may result in property damage, serious injury, or
death.
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
eective. People may not see or heed your warning signal. You must recognize
this fact and continue driving cautiously.
• 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.
• 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.
• 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.
• 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.

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Installation, Maintenance, and Service Manual
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Safety Messages
• It is important that you fully understand how to safely operate this warning system
before use.
• Only operate your vehicle and its light/sound system per 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, 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 firm grip on the mounting
surface. An improperly secured light could fall o of the vehicle causing injury and
damage.
• Holding power of magnetic mounting systems is dependent upon surface finish,
surface flatness, and thickness of the steel mounting surface. Therefore, to
promote proper magnetic mounting:
• Mounting surface and magnets must be kept clean, dry, and free of foreign
particles that prevent good surface contact.
• Ensure that mounting surface is flat.
• A magnet mounting system should not be used on vehicles with vinyl tops.
• To prevent sliding of light assembly on mounting surface, quick acceleration
and hard stops should be avoided.
Failure to follow these precautions may result in property damage, serious injury, or
death.

10 Valor®Light Bar
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An Overview of the Valor®Light Bar
An Overview of the Valor Light Bar
The Valor Light Bar is a single-level LED light bar with ROC™ (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. The light bar is shaped
to provide maximum intersection warning, the most dangerous situation in moving
trac.
LED Lights, Colors, and Flash Patterns
The light bar’s internal microprocessor 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 Valor lightheads can flash between red, blue, amber, or white.
Modular Connector System
The Valor Light Bar has a waterproof (IP67) external connector system for power and
communication to allow removal of the light bar from the vehicle without opening the
light bar or the vehicle hood. The Valor is protected against reversed polarity damage.
The Valor Light Bar may be installed in any vehicle with a 12-volt negative ground
electrical system.
Controller Options
Flash patterns are controlled through the light bar’s CAT5 communication cable. The
cable connects to the Serial Interface Module (Part Number 8583446), the Federal
Signal Six-Button Serial Controller (Part Number 8623133), the Three-Button Serial
Controller (Part Number 8623141), or the SmartSiren Series Platinum System or the
System control head only.
With the Serial Interface Module, the Valor Light Bar can be activated by Federal
Signal light bar controllers, SignalMaster directional-light controllers, or by individual
low-current switch boxes.