Federal Signal Corporation 400 Series User manual

Model 400 Series Lights
256A424G
REV. A 610
Printed in U.S.A.
Installation Instructions

Warranty – Seller warrants all goods for five years on parts and 2-1/2 years
on labor, under the following conditions and exceptions: Seller warrants that
all goods of Seller's manufacture will conform to any descriptions thereof for
specifications which are expressly made a part of this sales contract and at the
time of sale by Seller such goods shall be commercially free from defects in
material or workmanship. Seller reserves the right at the Seller’s discretion to
“Repair and Return” or “Replace” any item deemed defective during the war-
ranty period. This warranty does not cover travel expenses, the cost of special-
ized equipment for gaining access to the product, or labor charges for removal
and reinstallation of the product. This warranty shall be ineffective and shall not
apply to goods that have been subjected to misuse, neglect, accident, damage,
improper maintenance, or to goods altered or repaired by anyone other than
Seller or its authorized representative, or if five years have elapsed from the
date of shipment of the goods by Seller with the following exceptions: lamps
and strobe tubes are not covered under this warranty. Outdoor warning sirens
and controllers manufactured by Federal Warning Systems are warranteed for
two years on parts and one year on labor. No agent, employee, representative
or distributor of Seller has any authority to bind the Seller to any representation,
affirmation, or warranty concerning the goods and any such representation, af-
firmation or warranty shall not be deemed to have become a part of the basics
of the sales contract and shall be unenforceable. THE FOREGOING WAR-
RANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES
OR MERCHANTABILITY, FITNESS FOR PURPOSE AND OF ANY OTHER
TYPE, WHETHER EXPRESS OR IMPLIED. These warranties shall not apply
unless Seller shall be given reasonable opportunity to investigate all claims for
allegedly defective goods. Upon Seller's instruction a sample only of allegedly
defective goods shall be returned to Seller for its inspection and approval.
The basis of all claims for alleged defects in the goods not discoverable upon
reasonable inspection thereof pursuant to paragraph 8 hereof must be fully
explained in writing and received by Seller within thirty days after Buyer learns
of the defect or such claim shall be deemed waived.
Industrial Systems
2645 Federal Signal Drive • University Park, IL 60484-3167
Tel: [phone] • Fax: [phone]
Email: [e-mail] • www.federalsignal-indust.com

Model 400 Series Lights 3
Contents
Safety Messages to Installers .............................................................5
Unpacking the Light.............................................................................6
Installation.............................................................................................7
Flat Surface (External Conduit) Mount...............................................7
Electrical Box Mount ........................................................................10
Ceiling Mount...................................................................................11
Obtaining Service, Assistance, and Parts........................................14
Replacing the Strobe Tube (400ST)...................................................15
Figures
Figure 1 7/8" drilled hole in bracket ..................................................... 7
Figure 2 Grommet in 7/8" drilled hole in bracket.................................. 8
Figure 3 Adapter plate attached .......................................................... 9
Figure 4 Ceiling mount....................................................................... 12
Figure 5 Strobe tube degradation...................................................... 16
Tables
Table 1 Kit contents.............................................................................. 6
Table 2 Replacement parts ................................................................ 14

Model 400 Series Lights
4
Vibratone is a registered trademark of Federal Signal Corp.
Keps is a registered trademark of ITW Shakeproof

Model 400 Series Lights 5
Safety Messages to Installers, Users, and
Maintenance Personnel
It is important to follow all instructions shipped with this product. This
device is to be installed by trained personnel who are thoroughly
familiar with the country electric codes and will follow these
guidelines as well as local codes.
The selection of mounting location for the device, its controls, and
wiring routing must be done under the direction of the facilities
engineer and the safety engineer. In addition, listed below are some
other important safety instructions and precautions you should follow:
• Read and understand all instructions before installing or
operating this equipment.
• Disconnect the light from the power supply before installing or
maintaining the light.
• After installation, test the light system to ensure that it is
operating properly.
• After testing is complete, provide a copy of this instruction sheet
to all operating personnel.
• The product nameplate, which may contain cautionary or other
information of importance to maintenance personnel, should not
be obscured in any way,
• Establish a procedure to routinely check the light system for
proper activation and operation.
Failure to follow all safety precautions and instructions may result in
property damage, serious injury, or death.
Note: A Model 350 Vibratone®Horn can be installed in the
lower housing of a Model 400 Series Light. It is usually more
convenient to install the audible device in the light before
attaching the light to the mounting surface. Therefore, it is
recommended that the audible device be installed (if applicable)
before proceeding.

Model 400 Series Lights
6
Unpacking the Light
After unpacking the light, examine it for damage that may have
occurred in transit. If the equipment has been damaged, do
not attempt to install or operate it. File a claim immediately with
the carrier stating the extent of the damage. Carefully check all
envelopes, shipping labels and tags before removing or destroying
them. Ensure that the parts listed in the KIT CONTENTS LIST are
included in the packing carton. If any parts are missing, please call
Federal Signal Customer Support at 708-534-4756.
Table 1 Kit contents
Qty. Description
2Hex. Head Mach. Screw, 1/4-20
2 Allen Head Set Screws, Cone Point
26-32 x 3/16" Hex Screws, Taptite
2 Nut, Keps®, 1/4-20
1 Cover Plate, Mounting Adapter
1 Cover, Self-Adhesive
1 Plate, Mounting Adapter
1 Bracket, Wall/Ceiling Mounting
1 Grommet

Model 400 Series Lights 7
Installation
There are three mounting methods for installing the Model 400
Series Lights:
• Flat Surface (External Conduit) Mount: Installer-supplied
mounting hardware, 1/2" conduit tting, and a condulet box are
required.
•Electrical Box Mount: Installer-supplied mounting hardware, a
4" x 4" electrical box, conduit, and wiring are required.
• Ceiling Mount: An installer-supplied 4" x 4" electrical box is an
option.
The next sections describe how to install the light using each
mounting method.
Flat Surface (External Conduit) Mount
To install the light on a flat surface:
1. See Figure 1. Drill a 7/8" hole in the wall/ceiling mounting
bracket. Use caution to avoid damaging the bracket.
Figure 1 7/8" drilled hole in bracket
7/8" DIA. HOLE
DRILLED BY INSTALLER
TO ACCEPT 1/2"
CONDUIT CONNECTOR
1-3/16" APPROX.
7/8"
APPROX.
290A1504

Installation: Flat Surface (External Conduit) Mount
Model 400 Series Lights
8
2. Install an installer-supplied 1/2" conduit tting into the hole.
3. Insert the nylon grommet in the large center hole in the side
of main frame casting of the light assembly (Figure 2).
Figure 2 Grommet in 7/8" drilled hole in bracket
DIMPLES
TOP AND
BOTTOM
ADAPTER PLATE (1) 6-32 SCREWS HEX HD. SLF TAP (2)
COVER PLATE (1)
1/4-20 SCREWS HEX HD. (2)
10-32 SET SCREWS ALLEN HD. (2)
MOUNTING BRACKET (1)
(WALL/CEILING MTG.)
GROMMET
LEXAN DOME
HOUSING
MAIN MOUNTING FRAME
290B1506
CUSTOMER
SUPPLIED
MTG. SCREWS (4)
ANCHORS (4)
SUPPORTING WALL
1/2" CONNECTOR
1/2" CONDUIT
1/2" CONDULET
WIRE NUTS (2)
1/2" CONDUIT
POWER SUPPLY
(MAKE CONNECTIONS HERE)
4. Attach the wall/ceiling mounting bracket to the main frame
casting using two 1/4"-20 x 1/2" hex-head machine screws.
Ensure that all wiring from the interior of the light passes
through the large center hole in the end of the bracket.
Route the wiring through the conduit fitting that was
installed in step 2.

Installation: Flat Surface (External Conduit) Mount
Model 400 Series Lights 9
5. Start the 10-32 x 3/4" cone-point set screws in the threaded
holes in the upper and lower edges of the wall/ceiling
mounting bracket.
6. Attach the cover plate to the adapter plate using the two
6-32 x 3/16" self-tapping screws.
7. See Figure 3. Attach the adapter plate to the mounting
surface using the appropriate installer-supplied hardware.
Figure 3 Adapter plate attached
DIMPLES
TOP & BOTTOM
ADAPTER PLATE (1)
1/4-20 SCREWS HEX HD. (2)
10-32 SET SCREWS ALLEN HD. (2)
MOUNTING BRACKET (1)
(WALL/CEILING MTG.)
GROMMET
LEXAN DOME
WIRE NUTS (2)
MOUNTING SCREWS (2)
4" X 4" ELECTRICAL BOX (1)
CUSTOMER SUPPLIED
MAIN MOUNTING FRAME HOUSING 290B1505B
8. Place the light/mounting bracket assembly over the adapter
plate and tighten the two cone point set screws. Ensure that
the screws engage the two dimples in the adapter plate.

Installation: Flat Surface (External Conduit) Mount
Model 400 Series Lights
10
9. Using the wires extending through the conduit fitting as a
guide, determine the length of the conduit necessary for the
installation as shown in Figure 3 on page 9.
SHOCK HAZARD—DO NOT connect wires when power
is applied. Failure to follow this warning could cause
serious injury or death.
Note: DO NOT make electrical splices within the wall/ceiling
mounting bracket.
10. Install conduit and a condulet box (both Installer-supplied),
as indicated. Splice the leads from the light to the power
leads in the condulet box. Connect the green lead (ground)
from the light to the condulet box by the most convenient
means. Insulate all splices.
Electrical Box Mount
To install the light in an electrical box:
1. Install a 4" x 4" electrical box, conduit and wiring as
necessary (all Installer-supplied).
2. See Figure 2 on page 8. Insert the nylon grommet in the
large center hole in the side of the light assembly main
frame casting.
3. See Figure 3 on page 9. Attach the wall/ceiling mounting
bracket to the main frame casting, using the two 1/4"-20 x
1/2" hex head screws. Make sure that all wiring from the
interior of the light passes through the large center hole in
the end of the bracket.
4. Install the adapter plate (supplied) on the 4" x 4" electrical
box, using the appropriate user-supplied hardware.
5. Start the two 10-32 x 3/4" cone point set screws in the
threaded holes in the upper and lower edges of the wall/
ceiling mounting bracket.

Installation: Electrical Box Mount
Model 400 Series Lights 11
SHOCK HAZARD—DO NOT connect wires when power
is applied. Failure to follow this warning could cause
serious injury or death.
6. Connect the green wire (ground) to the 4" x 4" electrical box.
Note: DO NOT make electrical splices within the wall/ceiling
mounting bracket.
7. Splice the light wires and audible device wires (if applicable)
to the electrical supply wires in the electrical box.
8. Place the assembled light and mounting bracket over the
adapter plate and tighten the two cone point set screws.
Make sure that the screws engage the two dimples in the
adapter plate.
Ceiling Mount
Model 400 Series Light can be mounted at on a ceiling or on
a 4" x 4" electrical box. Both of these mounting methods are
variations on those methods already described. However, the
wall/ceiling mounting bracket must be attached to the lower
housing of the light. If an audible device was installed, the
mounting bracket should be attached to the lower housing of
the light.
If the bracket is already attached, disregard the instructions
in this section and refer to the Flat Surface Mount instructions
on page 7 or the Electrical Box Mount instructions on page 10.
However, if it is necessary to attach the bracket to the light, see
Figure 4 on page 12 and follow these steps:
1. Remove the four slotted housing fastening nuts and lift the
lower housing from the light assembly.
2. Remove the grille cover plate from the bottom of the
housing by removing the four 6-32 Keps nuts and washers
at the bottom of the housing.

Installation: Ceiling Mount
Model 400 Series Lights
12
Figure 4 Ceiling mount
4" X 4" ELECTRICAL
BOX (1)
WIRE NUTS (2)
MOUNTING SCREWS (2)
CUSTOMER SUPPLIED
1/4-20 SCREWS HEX HD. (2)
10-32 SET
SCREWS ALLEN
HD. (2)
6-32 NUTS,
HOUSING
FASTENING (4)
MAIN
MOUNTING
FRAME
290B1507B LEXAN DOME (1)
COVER (1)
(SELF ADHESIVE)
1/4-20 HEX NUTS
EXT. KEPS (2)
HOUSING (1)
GROMMET (1)
MOUTNIG BRACKET (1)
(WALL/CEILING MTG.)
ADAPTER PLATE (1)
DIMPLES
(LEFT & RIGHT)

Installation: Ceiling Mount
Model 400 Series Lights 13
3. Install the nylon grommet in the center hole in the bottom of
the lower housing.
4. Route the light supply wires through the grommet that was
installed in step 3.
5. Attach the wall/ceiling mounting bracket to the lower
housing using two 1/4-20 x 1/2" hex head machine screws
and KEPS nuts (supplied).
6. Apply the self-adhesive cover over the holes on the side of
the main frame casting.
7. Reassemble the light following steps 1 and 2 in reverse
order.
8. Install the light on the ceiling following the Flat Surface
Mount instructions on page 7 or the Electrical Box Mount
instructions on page 10.

Model 400 Series Lights
14
Obtaining Service, Assistance, and Parts
Products returned for repair require a Return Authorization form.
To obtain service for the product, please contact the Federal Signal
Service Department at 708-534-4858.
For technical assistance, please call Federal Signal Technical
Support at 708-534-3424, extension 5823.
To order replacement parts, please call Federal Signal Customer
Support at 708-534-4756.
Table 2 Replacement parts
Description Part Number
Dome, Lexan, Red K8547C001-01
Dome, Lexan, Blue K8547C001-02
Dome, Lexan, Green K8547C001-03
Dome, Lexan, Amber K8547C001-04
Dome, Lexan, Clear K8547C001-05
Lamp (400R) K8107181
Interior Fresnel Lens, Clear (400ST) K8248C004-04
Tube, Strobe (400ST) K8107178
PC Board Assembly (400ST) K200D825
For instructions on how to service the Model 400ST Strobe Light,
see document no. 256A470 available at:
http://www.federalsignal-indust.com

Model 400 Series Lights 15
Replacing the Strobe Tube (400ST)
SHOCK HAZARD—Strobe and HID light systems generate high
voltages. Disconnect power and wait 5 minutes before opening
the unit. Do not apply power to the unit while the unit is open.
Failure to follow this warning could result in serious injury or
death.
HANDLE STROBE LAMPS CAREFULLY—Strobe lamps get
hot enough to burn you. Always allow these lamps to cool
before handling them. Strobe lamps are also pressurized and if
broken can result in flying glass. Always wear gloves and eye
protection when handling the lamps.
Failure to follow this caution may result in personal injury.
DO NOT TOUCH STROBE LAMPS WITH BARE HANDS—
Oil deposits on the glass portion of the strobe lamp can cause
the glass to fracture during use. If you are unsure if the glass
has been handled without gloves, clean the glass using a soft
cloth and isopropyl alcohol before installing the lamp.
As strobe lights are used, strobe tubes begin to darken causing
the light output to decrease. This darkening is characteristic of
strobe tubes and can be viewed through the top of the dome. It
will begin near the base of the tube and progress upward. Also,
as strobe tubes age, they may have a tendency to misfire (not fire
periodically).
After extended operation, occasionally check for strobe tube
degradation. Should the tube misfire, have a noticeable decrease in
light output, glow continuously, or darken to a point beyond that as
shown in Figure 5 on page 16, replace the tube. Not replacing the
strobe tube when any of the above conditions exist could cause a
breakdown of other components on the printed circuit board.

Replacing the Strobe Tube (400ST)
Model 400 Series Lights
16
To replace the strobe tube:
1. Remove the four screws and chrome load bearing plates which
secure the dome to the housing assembly. Remove the dome.
2. Remove the three 8-32 nuts and dome mounting plate that
secure the Fresnel lens to the mounting plate. Lift the lens away
from the housing assembly.
3. Grasp the strobe tube by its base and pull it out of the socket,
using a gentle rocking motion. Install a new strobe tube and
reassemble the light.
Figure 5 Strobe tube degradation
290A16502
B
A
A. NEW STROBE TUBE
B. A USED STROBE TUBE TENDS TO DISCOLOR IN THE AREAS
SHOWN AND SHOULD BE REPLACED.
© 2010 Federal Signal Corporation