Federal Signal Corporation VISION User manual

VISION®
WARNING SYSTEM
HARDWARE INSTALLATION AND MAINTENANCE INSTRUCTIONS
Price $15.00

TABLE OF CONTENTS Page
Section I - General Description ................................................................................................ 1-1
Section II - Specifications ......................................................................................................... 2-1
Section III - Installation ........................................................................................................... 3-1
Section IV - Operation .............................................................................................................. 4-1
Section V - Configuration ......................................................................................................... 5-1
Section VI - Service and Maintenance ..................................................................................... 6-1
i

ii
IMPORTANTWIRING INFORMATION
WARNING
The Vision® warning system is an advanced microprocessor based warning system. Unlike conventional light bars,
malfunctions and/or improper operation WILL result if proper installation procedures are not followed. Refer to the
accompanying diagram and pay special attention to the “DO & DON’T” list at the bottom of this page. To complete
the electrical installation, refer to paragraph 3-7.
DON’T
1. DON’T...Use in-line fuses, solenoids, or relays to switch
power to the 10 ga. red wire. Unreliable warning system operation
will result.
2. DON’T...Use solenoids or relays. Do not connect any other
products to this line. Unreliable warning system operation will
result.
3. DON’T...Connect to any other chassis ground or ground
shared with any other product. Unreliable warning system
operation will result.
4. DON’T...Connect to any black negative wire of the Vision
System. Unreliable warning system operation will result.
5. DON’T...Use any wire smaller than 10 ga. or a circuit
breaker less than 50 amps. Unreliable auxiliary device operation
will result.
DO
1. DO...Connect the 10 ga. red wire from the lightbar to one of
the two 50-ampere circuit breakers (installed as close to the
battery as possible and directly to the positive (+) battery termi-
nal). (Note: One 50-ampere circuit breaker can be used if the
auxiliary relays are NOT used.)
2. DO...Connect the 18 ga. red wire from the six pin connector
(J1-Pin 2) to a point on the fuse block that is powered in run and
start positions (F13 on 1993 Crown Victoria and F18 on 1993
Chevrolet Caprice). Use an in-line 2A fuse.
3. DO...Connect the 10 ga. black wire from the lightbar AND
the 18 ga. black wire from the six pin connector (J1-3) to the
fusible link at the front fender between the negative (-) battery
terminal and chassis ground. This is the ONLY chassis ground
allowed for these two wires.
4. DO...Connect the green wire from the six pin connector (J1-
Pin 4) to chassis ground.
OPTIONAL AUXILIARY RELAY POWER:
5. DO...Connect a 10 ga. wire to the load side of the other 50-
ampere circuit breaker. Route it through the hole labeled +BAT on
the interface/relay unit and attach it to LUG 1 on the circuit
board.

SECTION I
GENERAL DESCRIPTION
Three auxiliary relay outputs are available for
control of auxiliary lights and accessories.
An optional user-supplied switch, such as a foot
switch, may be used to activate primary warning
lighting. An interface is also provided to activate a
Federal Model SS2000 SmartSiren® from either the
Vision’s Control Head or the optional user-supplied
switch.
An optional rear directional light, called the
SignalMaster™, provides additional warning capabil-
ity using a common control. The SignalMaster has
programmable light patterns which provide supple-
mental warning for any hazardous situation.
The Control Head’s LED display indicates which
lights are illuminated. When the optional SignalMas-
ter is installed, the Control Head’s LED display
simulates the light pattern being executed by the
directional light.
The warning system is protected against re-
versed polarity damage. Relay outputs are protected
by automotive-type fuses.
The Vision warning system may be installed in
any vehicle with a 12-volt NEGATIVE ground
electrical system. The Interface/Relay Unit may be
installed in the trunk or under the seat. For simple
installation: connection between the Control Head
and the Interface/Relay Unit is via a modular tele-
phone cable with standard modular phone connectors
at both ends, and connection between the Interface/
Relay Unit and the lightbar is via a multi-conductor
cable with connectors at both ends.
Other advanced features of the Vision warning
system include:
• High degree of reliability through the use of
CMOS microprocessor and other integrated
circuits.
• Modular construction with easily replaceable
circuit boards, domes and lamps to greatly
reduce spare parts inventory.
• Quiet, smooth, precise and efficient positioning
stepper motors control parabolic reflectors and
have a longer life than conventional DC motors.
1-1
Figure 1-1. Vision® Warning System.
The Federal Vision® warning system (figure
1-1) is a full-featured, programmable warning light
system. State-of-the-art microprocessor based tech-
nology is used to produce a warning light system
with a super-compact, 1" thin control head. All
warning system functions and programmable fea-
tures are available at the Control Head. Replaceable
switch function labels are provided for identification
of Control Head switches.
V-shaped construction lets the Vision warning
system maximize light warning efficiency at crucial
45°angles. The individual domes are shaped to
eliminate critical dome angles, which reflect rather
than transmit light in other light bars, significantly
improving light transmission (brightness).
Vision’s revolutionary aerodynamic styling
provides superior vehicle fuel efficiency and top
speed.
Each of the warning system’s seven modular,
self-contained and independent lights are pre-
programmed to provide a wide selection of warning
light patterns. Available patterns include: rotate at
90, 120 or 175 flashes per minute; oscillate to the
front, rear, sides and/or angled; as well as steady
burn and flashing. Pattern selection can be per-
formed during or after installation without disassem-
bly, wiring changes, or special tools.
Take-down and alley lights have horizontal
tracking capability for use as spotlights, or they may
be programmed to home to a predetermined position.

SECTION II
SPECIFICATIONS
2-1
2-1. ELECTRICAL.
Input Voltage .................................................................................................... 11VDC to 16VDC.
Polarity ............................................................................................................ Negative ground only.
Operating Temperature Range........................................................................ -30°C to +65°C.
Standby Current ............................................................................................... 2.5 amperes (nominal).
Operating Current ............................................................................................ 30 amperes (nominal).
(SignalMaster and auxiliary functions deactivated)
2-2. PHYSICAL.
Dimensions:
Interface/Relay Unit
Height ................................................................................................. 1-3/8" (3.5cm).
Width .................................................................................................. 6-3/8" (16.2cm).
Length................................................................................................. 4-5/16" (11cm).
Net Weight ......................................................................................... 1 lb. (.454kg).
Control Head
Height ................................................................................................. 2-5/16" (5.87cm).
Width .................................................................................................. 6-3/4" (17.15cm).
Length................................................................................................. 1.0" (2.54cm).
Net Weight ......................................................................................... 6-1/2 oz. (0.183kg).
Lightbar
Height ................................................................................................. 5-7/8" (15cm).
Width .................................................................................................. 47-3/4" (121.3cm).
Length................................................................................................. 28" (71.12cm).
Net Weight ......................................................................................... 42 lbs. (30.45kg).
Shipping Weight ............................................................................................... 67 lbs. (30.45kg).
2-3. FEATURES SUMMARY.
• V-shaped construction.
• Seven multi-function 50 watt lamp modules.
Rotation at 90FPM, 120FPM, and 175FPM.
Oscillation to front, rear, and sides.
Alley/take-down lights with manual (sweep or single step) positioning capability.
• Three auxiliary relay-controlled outputs.
• Interface for Federal Model SS2000 SmartSiren activation.
• Mode 3 activation via foot switch (optional).
• User-selectable keyboard configurations with pre-programmed light patterns.
• Optional rear SignalMaster directional light.
• Unauthorized reprogramming prevention.

3-1
SECTION III
INSTALLATION
SAFETY MESSAGE TO INSTALLERS
OF
WARNING LIGHT SYSTEMS
WARNING
The lives of people depend on your safe instal-
lation and servicing of Federal products. It is
important to read and follow all instructions
shipped with the products. In addition, listed
below are some other important safety instruc-
tions and precautions you should follow:
Before Installation
Qualifications
• To properly install a warning light system: you
must have a good understanding of automo-
tive electrical procedures and systems, along
with proficiency in the installation and service
of safety warning equipment.
During Installation
• 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.
• Locate the control head so the vehicle, controls,
and microphone can be operated safely.
• A light system is a high current device. In
order for it to function properly, separate
ground (-) and positive (+) connections must
be made. They should be connected to the
battery terminals. A suitable fuse must be
installed in the positive lead as close to the
battery as practical.
• The Vision warning system is an advanced
microprocessor based warning system. Unlike
conventional light bars, low voltage conditions
(less than 11VDC) may cause it to malfunction
or fail to operate. Installation procedures
MUST produce reliable and durable ground (-)
and positive (+) connections. In addition: the
vehicle battery, charging system, and installa-
tion wiring MUST have the capacity to supply
consistent warning system power at rated
current and voltage levels.
• DO NOT install equipment or route wiring or
cord in the deployment path of an air bag.
• DO NOT install a two-way radio antenna on
the lightbar.
• Install the lightbar at least 18-inches away
from any two-way radio antenna.
• DO NOT drill additional holes in the lightbar,
or install auxiliary devices on the lightbar.
• When drilling into a vehicle structure, be sure
that both sides of the surface are clear of any-
thing that could be damaged.
• If wiring is shorted to vehicle frame, high
current conductors can cause hazardous
sparks resulting in electrical fires or flying
molten metal.
After Installation
• After installation, test the warning light
system to ensure that it is operating properly.
• Test all vehicle functions, including horn
operation and vehicle light systems, to ensure
proper operation.
• After testing is complete, provide a copy of
these instructions to the instructional staff
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 all safety precautions and
instructions may result in property damage, serious
injury, or death to you or others.

3-2
WARNING
When installing equipment inside air bag
equipped vehicles, 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
effectiveness of the air bag, damage the air bag,
or potentially damage or dislodge the equip-
ment, causing serious injury or death to you
or others.
3-1. UNPACKING.
After unpacking the Vision, examine it for
damage that may have occurred in transit. If the
equipment has been damaged, file a claim immedi-
ately with the carrier stating the extent of damage.
Carefully check all envelopes, shipping labels and
tags before removing or destroying them.
3-2. COLORED DOME INSERT OPTION
INSTALLATION.
WARNING
To provide proper warning colors to the front
and/or rear if dome inserts are used, a clear
dome must be used with the colored inserts.
A. Remove and retain the two Torx head
screws which secure the dome to the pod.
B. Carefully remove the dome and set it aside.
C. Place the front or rear insert in position
and ensure that the locating notches are properly
positioned on the locating ribs as shown in figure 3-1.
If applicable, repeat with the other insert.
CAUTION
Excessive tightening of the Torx head screws
will damage the screws.
Figure 3-2. Block Wiring Diagram.
Figure 3-1. Dome Insert Installation.
D. Replace the dome and secure with the
previously removed Torx head screws.
3-3. LIGHTBAR INSTALLATION.
WARNING
Improper warning system and/or two-way
radio system operation may result if a two-way
radio antenna is installed on, or within
18-inches of, the lightbar. Before permanent
installation of the lightbar or a two-way radio
antenna, test the warning system and two-way
radio system. DO NOT install a two-way radio
antenna on the lightbar.
Some installations may require relocation of
the two-way radio antenna to a trunk or fender
location.
Warning system failure may result if
additional holes are drilled in the lightbar,
or if auxiliary devices are installed on the
lightbar. DO NOT drill additional holes in the
lightbar, or install auxiliary devices on the
lightbar.
Before performing any installation, see figure 3-
2 (block wiring diagram); plan all wiring and cable
routing. Ensure that the lightbar is installed on the
vehicle roof in accordance with the instructions
packed with the mounting kit.
3-4. INTERFACE/RELAY UNIT MOUNTING
LOCATION SELECTION.
CAUTION
The Vision Interface/Relay Unit housing is
NOT waterproof. It must be mounted in a
location which is sheltered from falling rain,
snow, standing water, etc. Also, it must be
installed in an adequately ventilated area.
Never install near heater ducts.
Do not mount the Vision Interface/Relay Unit
under the vehicle’s hood.

3-3 Figure 3-4. Control Head Bracket Assembly.
When selecting a mounting location for the
Vision Interface/Relay Unit and the control head, it is
necessary to keep in mind that the control head cable
is 20-feet long and the power cable is 4-feet long.
Plan all wiring and cable routing before performing
any installation.
Some possible Interface/Relay Unit mounting
locations are: under the dash, under the front seat, or
in the trunk (under the rear deck, near the rear seat
speakers, if vehicle is so equipped).
Using the supplied mounting bracket will allow
the Interface/Relay Unit to be easily removed for
wiring and servicing, should it be needed.
3-5. INTERFACE/RELAY UNIT MOUNTING
BRACKET.
To install the Interface/Relay Unit using the
mounting bracket, proceed as follows:
A. Use the mounting bracket as a template
and scribe two drill positioning 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.
NOTE
If desired, the #14 thread-forming screws
may be used in place of the 1/4-20 x 3/4 hex
head screws.
B. Drill two mounting holes at the position
marks.
C. Secure the mounting bracket to the mount-
ing surface with (2 each) 1/4-20 x 3/4 hex head
screws, 1/4 split lockwashers and 1/4-20 hex nuts as
shown in figure 3-3.
3-6. CONTROL HEAD INSTALLATION.
Several control head mounting methods are
available. The mounting method used will depend on
the mounting location, available room, and user
preference.
CAUTION
Unreliable switch activation and loss of “tactile
feedback” will result if the control head mount-
ing method allows movement. DO NOT mount
the control head on padded surfaces.
Choose a location for the control head that
allows the vehicle, controls, and microphone to be
operated safely at all times.
Figure 3-3. Mounting Bracket Installation.
A. See figure 3-4. The supplied hinged mount-
ing bracket enables the control head to be mounted in
a variety of positions. Positioning the bracket above
the unit allows mounting the control head on the
underside of the dash. Positioning the bracket below
the unit will permit mounting on any horizontal
surface. To mount the control head using the bracket,
proceed as follows:
1. Assemble a bracket to the control head
using the 6-32 x 1/4 screws and #6 lockwashers.
Assemble the other bracket to the control head/
bracket assembly using the 1/4-20 x 3/4 hex head
screws and 1/4" lockwashers as shown in figure 3-5.
NOTE
The brackets are not symmetrical. After assem-
bling the brackets to the control head, ensure
that the assembly can be properly positioned
at the intended mounting location. If proper
positioning cannot be achieved, reverse the
bracket.

Figure 3-5. Control Head and Bracket Installation.
3-4
2. Use the mounting bracket as a tem-
plate and scribe two drill positioning marks at the
selected mounting location.
CAUTION
Before drilling holes in ANY part of a vehicle,
be sure that both sides of the mounting sur-
face are clear of parts that could be damaged;
such as brake lines, fuel lines, electrical wiring
or other vital parts.
3. Drill two mounting holes at the posi-
tion marks.
4. Secure the mounting bracket to the
mounting surface with the #10 thread-forming
screws as shown in figure 3-5.
B. If the control head/bracket assembly cannot
be secured to the firm mounting surface with screws,
remove the brackets and use the supplied adhesive-
backed velcro hook-and-loop pads to attach the unit
to a firm, flat surface.
3-7. ELECTRICAL INSTALLATION.
WARNING
Failure to observe this WARNING may result
in fire, burns or blindness.
If shorted to vehicle frame, high current con-
ductors can cause hazardous sparks resulting
in electrical fires or molten metal.
DO NOT connect this system to vehicle bat-
tery until ALL other electrical connections
are made and mounting of all components is
complete.
Verify that no short circuits exist, before con-
necting to the Positive (+) battery terminal.
To complete this portion of the installation, refer
to the block wiring diagram (figure 3-2) and figure 3-
6. Proceed as follows:
A. Lightbar Connections.
The lightbar is completely wired at the
factory and does not require any additional internal
wiring. All the conductors necessary for control of all
functions are contained in the cables.
1. Route the lightbar power cable and the
control cable into the vehicle.
2. Route the control cable near the
location of the previously installed Interface/Relay
Unit and secure the cable with user-supplied clamps
and hold-downs as required.
3. Plug the control cable’s connector into
the mating connector on the Interface/Relay Unit.
CAUTION
Before drilling holes in ANY part of a vehicle,
be sure that both sides of the mounting sur-
face are clear of parts that could be damaged;
such as brake lines, fuel lines, electrical wiring
or other vital parts.
4. If necessary, drill a hole in the vehicle
firewall. Place a grommet or similar device in the
hole to protect the wires against damage from rough
edges. Route the power cable into the engine com-
partment.
To protect the wire, a separate circuit
breaker must be connected as close as practical to the
positive (+) battery terminal. FUSES ARE NOT
ACCEPTABLE. See figures 3-2 and 3-6. Install the
supplied two 50-ampere circuit breakers (Federal
Part No. 8474176). DO NOT remove the jumper on
the battery side of the circuit breakers. Connect the
red wire to one of the 50-ampere circuit breakers.
Do NOT make any connections to the
battery until all other wiring is complete.
B. Interface/Relay Unit Power Cable
Connections.
The Interface/Relay Unit power cable,
included in the carton, is equipped with a six-pin
plug that mates with the connector on the rear of the
Interface/Relay Unit (see figures 3-7 and 3-8). Addi-
tional wire (the same gauge or heavier) may be
spliced to the leads as required. The various wires on
the connector must be connected as follows:

3-5
NOTE
Use electrical tape to insulate ANY unused
power cable wires.
1. Connection to Power Source (see
figure 3-8).
The Vision must operate from a 12 volt
NEGATIVE ground vehicle electrical system. There-
fore, before making any electrical connections, verify
the polarity of the vehicle electrical system ground.
NOTE
Transient noise pulses caused by the automo-
tive power system or surge currents due to
switching inductive or incandescent lamp loads
may cause malfunctions in the Vision if
proper wire routing is not followed.
The Interface/Relay Unit red (positive) and
black (negative) power cable leads should be
as short and direct to the battery or fuse
block as possible. Do NOT splice them to
lightbar or accessory power leads.
The black (negative) power cable lead should
NOT be connected to the vehicle chassis.
Power for the Interface/Relay Unit
(fused at 2-amperes) can be obtained from the
vehicle’s fuse block, or a 2-ampere fused, switched
circuit.
Figure 3-6. Battery Connections.
Figure 3-7. Rear View of Interface/Relay Unit.
NOTE
The Vision system does not have an on-off
switch. If Interface/Relay Unit power is ob-
tained directly from the vehicle battery, the
system will continuously draw approximately
2.5A and will eventually discharge the vehicle’s
battery. It is recommended that the Interface/
Relay Unit power be obtained from a vehicle
circuit that is powered in the run and start
positions (see table 3-1). Power can also be
obtained from a user-supplied switch (current
capacity of at least 2 amps).
CAUTION
Before drilling holes in ANY part of a vehicle,
ensure that both sides of the surface are clear
of parts that could be damaged; such as brake
lines, fuel lines, electrical wiring or other
vital parts.
a. Connect the green power cable
lead to the vehicle chassis as close as practical to the
Interface/Relay Unit. Scrape paint away from the
selected bolt hole to assure a good electrical connec-
tion to the chassis.
b. Route the red (+) power cable lead
to the fuse block (see table 3-1) or user-supplied
switch. When the red (+) power cable lead is routed
to the fuse block, install the fuse clip adapter (sup-
plied) as shown in figure 3-8.
Figure 3-8. Interface/Relay Unit Power Cable and
Fuse Clip Adapter Installation..

3-6
c. To protect the wires, use an in-
line fuseholder and 2-ampere fuse (not supplied). The
fuseholder and fuse should be installed in the red (+)
lead as close as practical to the power source.
d. Route the black (-) power cable
lead through the previously drilled hole into the
engine compartment, and through existing clamps
and holders toward the battery. DO NOT make any
connections to the battery until all other wiring is
complete.
2. Optional Foot Switch.
The optional foot switch function is
activated by momentarily grounding the foot switch
input using a user-supplied foot switch (Federal
Model SWF) or other equivalent momentary contact
SPST switch.
a. Install the foot switch in a loca-
tion which allows the vehicle, controls, and micro-
phone to be operated safely at all times. In addition,
the foot switch should be installed in a location which
allows minimum reaction time in an emergency
situation.
b. Connect one side of the switch to
a RELIABLE chassis ground using #18AWG or
larger wire.
c. See figure 3-8. Connect the other
side of the switch to the power cable’s white wire
using #18AWG or larger wire.
3. Optional SS2000 Interface.
The optional SS2000 interface function
will activate the Federal Model SS2000 SmartSiren®
pursuit function using the Vision control head or
optional foot switch described above.
a. Using #18AWG or larger wire,
connect the power cable’s gray wire to the gray wire
in the SS2000’s power cable.
b. Connect +12V to LUG1 as de-
scribed in paragraph 3-7.C. below.
C. Auxiliary Connections.
NOTE
Steps 3-7.C.1. through 3-7.C.6. below are nec-
essary ONLY if auxiliary devices are to be
controlled by the warning system.
The Vision is configured at the factory to
satisfy most installation requirements. Before
proceeding with installation, refer to the supplied
Operation and Configuration Instructions manual for
a description of the “standard” keyboard configura-
tions and for instructions on how to change the
configuration (if necessary).
The Vision provides one terminal strip
(TB1) for control of auxiliary lights and accessories. A
total of three fused relay-controlled outputs are
available.
Each output switches a nominal +12-volts
to the controlled device. Do NOT use the black wire
in the Interface/Relay Unit power cable for grounding
the switched device(s). Ground the switched devices
separately.
Refer to the installation instructions
provided with the auxiliary devices for additional
precautions and details.
Fuse current ratings and possible uses for
each output are shown in table 3-2.
Complete the wiring to the accessories as
follows:
1. Remove the chassis cover by loosening
the 2 screws on the bottom of the Interface/Relay
Unit. See figure 3-7. Slide the cover to expose the
terminal strip.
2. Route a #10AWG red wire through the
hole labeled +BAT and attach it to the large lug-type
Outputs Fuse Rating Possible Usage
A - C 10 amperes Auxiliary Devices
(Headlight Flasher,
Grille Lights, Rear
Deck Lights, Trunk
Release, etc.)
Table 3-2. Output Ratings.
Make of Automobile 1993 1992 1991 1990-89
Chevrolet Caprice Fuse 18 Fuse 18 Fuse 18 TURN
B/U
Ford Crown Victoria Fuse 13 Fuse 13 Fuse 13 Fuse 18
Table 3-1. Fuse Block Connection.

3-7
terminal (LUG1) on the circuit board. Since this wire
provides the power source for all relay-switched
auxiliary functions, a good mechanical and electrical
connection here is important. Also, ensure that there
are no loose wire strands which may cause a short
circuit.
3. Route this wire through the previously
drilled hole into the engine compartment and
through existing clamps and holders toward the
battery.
4. To protect the wire, Vision, and the
auxiliary outputs, connect it to the UNUSED LOAD
SIDE of the previously installed 50-ampere circuit
breakers. Do NOT make any connections to the
battery until all wiring is complete.
5. See figures 3-7 and 3-9. Connect wires
from the accessories to TB1-1 through TB1-3 as
applicable. Refer to the instructions packed with the
accessories for proper wire gauge, current require-
ments, and any additional instructions. Do NOT
exceed fuse ratings shown in table 3-2.
6. Replace the chassis cover. Slide it
forward and secure with the two screws.
D. Control Head Connections.
All connections between the Vision control
head and Interface/Relay Unit are accomplished by a
single 20-foot telephone-type cable (provided). It is
terminated with modular-type connectors on each
end.
CAUTION
The unit will not operate if the telephone-type
cable is improperly wired. If it is necessary to
shorten the 4 conductor telephone-type cable,
ensure that the connections made to the
modular connector are exactly the same as the
original cable connections.
Figure 3-9. Interface/Relay Unit Circuit Board.
To complete this portion of the installation,
proceed as follows:
1. Route the 20-foot cable between the
control head and the Interface/Relay Unit. Secure the
cable with user-supplied clamps and hold downs as
required.
2. Insert the modular connector in the
mating receptacle on the back of the Interface/Relay
Unit. Secure with user-supplied clamps and/or wire
ties to provide strain relief.
3. Insert the other modular connector in
the receptacle on the control head. Secure with user-
supplied clamps and/or wire ties to provide strain
relief.
3-8. INSPECTION AND FINAL INSTALLATION.
A. See figure 3-3. Secure the Interface/Relay
Unit to the mounting bracket with the BLACK 1/4-20
x 7/16 hex head screws and 1/4 split lockwashers.
Ensure all fasteners are properly tightened.
B. Before connection to the power source,
perform a visual check of all connections and wiring.
C. Ensure that there are no loose wire strands
or other bare wire which may cause a short circuit.
Also, all wires must be protected from any sharp
edges which could eventually cut through the insula-
tion.
D. Use an ohmmeter to verify that a short
circuit does NOT exist between the positive (+) and
negative (-) power cable leads. Also, there must be
NO short circuits between the positive (+) wires and
the vehicle chassis.
WARNING
Failure to observe this warning WILL result
in severe instantaneous damage to the Vision
system.
The reverse polarity protection WILL NOT
protect against red (+) and black (-) wires
mixed in the same connection. Ensure that
all positive (red) and negative (black) wires
are properly connected together (reds to reds,
and blacks to blacks) before connecting to the
power source.
E. After performing steps A through D,
connect the black (-) wires to the fusible link at the
front fender between the negative (-) battery termi-
nal and chassis ground. This is the ONLY chassis
ground allowed for these wires. See figure 3-6. Secure
mechanical and electrical connections are required.

3-8
F. See figure 3-6. Connect all red (+) wires to
the positive (+) terminal of the power source. Again,
secure mechanical and electrical connections are
required.
3-9. REPLACEABLE FUNCTION LABELS.
NOTE
Before installing the function labels, it is nec-
essary to understand which functions are
activated by the individual switches. Read
and understand Section I Operation and
Section II Configuration in the supplied Oper-
ation and Configuration Instructions before
proceeding.
See figure 3-10. Replaceable function labels
identify all switches on the control head. Sheets of
applicable function legends are supplied.
To install the function legends, proceed as
follows:
A. Disconnect the control head cable at the
control head. Remove the control head from its
bracket (if used).
B. Remove and retain the four screws from the
rear of the control head. Separate the control head
rear housing (base) from the bezel. Lift the keyboard
assembly out through the bezel.
NOTE
It is not necessary to separate the keyboard
assembly’s two circuit boards.
C. Place the keyboard assembly on the work
surface face down. See figure 3-11. Using a small
longnose pliers or tweezers, carefully grasp the white
edge of the top legend strip and slide the strip out of
the keyboard.
D. Select the appropriate labels from the
supplied sheets of function legends. Peel the labels
from the sheets and apply to the legend strip in the
area provided as shown in figure 3-11. Slide the
legend strip back into the keyboard.
E. Repeat the above procedure for the bottom
legend strip.
F. Reassemble the control head. Reassemble
the control head in its bracket (if used), and insert
the modular connector in the receptacle.
3-10. TESTING AFTER INSTALLATION.
NOTE
The Vision warning system is supplied with
Keyboard Configuration 2 selected.
Figure 3-10. Control Head Disassembly.
Figure 3-11. Replaceable Function Labels.
Before testing, read and understand Section I
Operation in the supplied Operation and Configura-
tion Instructions. After installation is complete, test
all warning system functions to ensure that all
functions and controlled devices operate as intended.
Test all vehicle functions, including horn operation
and vehicle light systems, to ensure proper operation.
Configuration is described in Section II Configu-
ration in the supplied Operation and Configuration
Instructions.

SECTION IV
OPERATION
SAFETY MESSAGE TO OPERATORS OF
FEDERAL SIGNAL LIGHT SYSTEMS
WARNING
The lives of people depend on your safe opera-
tion of Federal products. It is important to read
and follow all instructions shipped with the
products. In addition, listed below are some
other important safety instructions and precau-
tions you should follow:
Qualifications
• To properly use a light system: you must have
a good understanding of general vehicle opera-
tion, a high proficiency in the use of safety
warning equipment, and thorough knowledge
of state and federal UNIFORM TRAFFIC
CODES.
Signaling Limitations
• Be aware that the use of your visual signaling
devices does not give you the right to force your
way through traffic. Your emergency lights and
actions are REQUESTING the right-of-way.
• Although your warning system is operating
properly, it may not alert everyone. People
may not hear, 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 or man-made
objects are between your vehicle and others,
such as when you raise your hood or trunk lid.
If these situations occur, be especially careful.
• The control head’s LED display emulates the
light pattern(s) being executed by the warning
system. The display is intended ONLY as a
guide and NOT as an indication of proper
warning system operation. Before using the
warning system, its operation should be ob-
served from outside the vehicle.
Driving Limitations
• At the start of your shift, you should ensure
that the light system is securely attached to
the vehicle and operating properly.
• If the unique combination of emergency vehicle
equipment installed in your vehicle has resulted
in the light/siren controls being installed in a
position that does not allow you to operate them
by touch only, OPERATE CONTROLS ONLY
WHILE YOUR VEHICLE IS STOPPED.
• If driving conditions require your full attention,
you should avoid operating the light/siren
controls while the vehicle is in motion.
Continuing Education
• File these instructions in a safe place and refer
to them periodically. Give a copy of these in-
structions to new recruits and trainees.
Failure to follow these safety precautions may
result in property damage, serious injury, or death to
you, to passengers, or to others.
IMPORTANT
System configuration and any changes to the
“standard” keyboard configurations (if any)
MUST be provided to the operator by the in-
staller or person responsible for programming.
It is the operator’s responsibility to under-
stand how his particular system is configured
(programmed) to operate.
OPERATING INSTRUCTIONS
The Vision control head is designed to assist the
operator’s selection of functions. Each control head
switch is recessed and aids guiding the operator’s
finger to the switch’s center for activation. When a
switch is pressed, “tactile feedback” provides function
selection indication as follows: a click is felt, a beep is
heard, the selected function’s LED is illuminated,
and the control head’s V-shaped LED display indi-
cates which warning system lights are illuminated. If
the optional SignalMaster directional light is in-
stalled, the control head display emulates the direc-
tional light pattern being executed.
Specific operating instructions are provided in
the supplied Operation and Configuration Instruc-
tions.
4-1

SECTIONV
CONFIGURATION
WARNING
Property damage, serious injury, or death to
you or others may result if the Vision warning
system is improperly configured. Configuration,
if required, is to be performed at the time of
installation. It is NOT intended for operators
to “cus-tomize” the Vision’s operation for their
individual preferences. It is the USER’s re-
sponsibility to determine compatibility, suita-
bility, and ensure proper configuration of the
Vision warning system.
The person responsible for configuration
MUST be familiar with local codes and proce-
dures for safe emergency vehicle warning
system operation.
CONFIGURATION INSTRUCTIONS
The Vision is an extremely versatile and config-
urable warning system. Take-down lights, alley
lights, secondary and primary warning light pat-
terns, and the optional SignalMaster directional
warning signals are all available with the “standard”
keyboard configurations. Also, control of auxiliary
devices (headlight flashers, grille lights, etc.) is
available.
For configuration instructions, refer to the
supplied Operation and Configuration Instructions.
5-1

SECTIONVI
SERVICE AND MAINTENANCE
6-1
SAFETY MESSAGE TO PERSONNEL SERVICING
FEDERAL SIGNAL WARNING SYSTEMS
WARNING
The lives of people depend on your safe servic-
ing of Federal products. It is important to read
and follow all instructions shipped with the
products. In addition, listed below are some
other safety instructions and precautions you
should follow:
• Read and understand all instructions in this
manual before servicing the warning system.
• To properly service a warning system: you
must have a good understanding of automo-
tive electrical procedures and systems, along
with proficiency in the installation and service
of safety warning equipment.
• Electronic circuit repairs must be performed
by a qualified and competent electronic
technician.
• DO NOT connect this system to the positive
terminal of the battery until servicing is com-
plete, and you have verified that there are no
short circuits to ground.
• In order for the warning system to function
properly, the ground connection must be made
to the NEGATIVE battery terminal.
• After repair, test the warning system to
ensure that it is operating properly.
Failure to follow all safety precautions and
instructions may result in property damage, serious
injury, or death to you or others.
6-1. GENERAL.
Most of the component electronic parts used in
the Vision are standard items that can be obtained
from any TV or electronics shop. In order to reduce
equipment down-time, Federal recommends that an
entire printed circuit board be replaced. The printed
circuit boards are relatively inexpensive allowing you
to keep an adequate supply in your repair shop.
For warranty service, contact your local Dis-
tributor.
The factory can and will service your equipment
or assist you with technical problems that cannot be
handled satisfactorily and promptly locally.
Communications and shipments should be
addressed to:
Service Department
Federal Signal Corporation
2645 Federal Signal Drive
University Park, IL 60466
1-800-433-9132
(In Illinois) 708-534-3400
6-2. CONTROL HEAD.
The Vision control head consists of two circuit
boards stacked on top of each other. See figure 6-1.
To disassemble the control head, proceed as follows:
A. Disconnect the control head cable at the
control head. Remove the control head from its
bracket (if used).
B. Remove and retain the four screws from the
rear of the control head. Separate the control head
rear housing (base) from the bezel. Lift the keyboard
assembly out through the bezel.
Figure 6-1. Control Head Disassembly.

C. Separate the two circuit boards by gently
pulling them apart.
D. Disconnect the green wire at the stud on
the keypad circuit board.
E. After repair or replacement, reconnect the
green wire and reassemble the control head. Reas-
semble the control head in its bracket (if used), and
insert the modular connector in the receptacle.
6-3. INTERFACE/RELAY UNIT.
A. General.
Any competent electronic technician should
have little difficulty in tracing a malfunction, should
any occur. For emergency replacement of any of the
small components, care must be used when soldering.
Heat easily damages transistors, capacitors and
circuit boards. It is therefore advisable to use
longnose pliers or a similar heat sink on the lead
being soldered.
CAUTION
To avoid damage to the unit, disconnect all
red wires to the unit at the battery
before proceeding.
B. Removal for Servicing.
When removing the chassis for servicing,
loosen the two hexagon head screws on the underside
of the unit, near the front edge. Slide the entire
chassis out of the case as shown in figure 6-2.
C. Printed Circuit Board Removal.
The Vision Interface/Relay Unit consists of
one circuit board. See figure 6-3.
To remove the circuit board, proceed as
follows:
1. Disconnect the wires from the terminal
strip TB1.
2. Disconnect the large red wire at
LUG1.
3. Unplug the control head cable and
lightbar control cable connectors.
4. Unplug the connector at J1 on the
circuit board.
5. The circuit board is secured to the
chassis by four stand-offs. Depress the locking tab on
each stand-off and gently lift the circuit board off the
stand-offs.
D. Control Head Fuse.
A solder-in sub-miniature fuse (F5 on the
circuit board) provides short-circuit protection for the
control head and cable. F5 is located between R12
and R13 (near J1) on the circuit board. Failure of this
fuse, although unlikely, will cause the Vision to be
completely inoperative. If failure of F5 is suspected,
proceed as follows:
1. Remove the circuit board as described
in 6-3.C. above.
2. Check the fuse for continuity with an
ohmmeter.
3. If fuse failure has occurred, replace
with an EXACT replacement (refer to paragraph 6-
6.).
NOTE
Failure of the control head fuse is usually the
result of a shorted control head cable, or the
control head cable was damaged during instal-
lation. Ensure that the cause of F5’s failure is
located and repaired before reapplying power
to the unit.
6-4. LIGHTBAR.
A. General.
Any competent electronic technician should
have little difficulty in tracing a malfunction, should
any occur. For emergency replacement of any of the
small components, care must be used when soldering.
Heat easily damages transistors, capacitors and
circuit boards. It is therefore advisable to use
longnose pliers or a similar heat sink on the lead
being soldered.
Figure 6-2. Chassis Removal. 6-2

Figure 6-3. Interface/Relay Unit Circuit Board.
CAUTION
To avoid damage to the unit, disconnect all
red wires to the unit at the battery
before proceeding.
B. Cover Removal.
See figure 6-4. Remove and retain the four
screws which secure the cover on the lightbar. Slide
the cover back slightly and carefully lift to remove.
C. Printed Circuit Board Removal.
The Vision lightbar contains two (three if
optional SignalMaster is installed) circuit boards. See
figure 6-5.
To remove a circuit board, proceed as
follows:
1. Remove and retain the fasteners which
secure the circuit board to the lightbar.
CAUTION
Unpredictable operation may result if motor
cables, or lamp driver cables, are mixed.
Before removing cables, mark the cables for
proper reconnection when reassembling.
WARNING
Failure to observe this warning WILL result
in severe instantaneous damage to the Vision
system.
The reverse polarity protection WILL NOT
protect against reversed red (+) and black (-)
wires to individual circuit boards. Ensure
that all positive (red) and negative (black)
wires are properly reconnected when replac-
ing a circuit board.
2. Disconnect wires and cables as appli-
cable.
3. Repair or replace the circuit board as
required.
Figure 6-4. Lightbar Cover Removal.
6-3

Figure 6-5. Lightbar Circuit Boards.
6-4
D. Pod Servicing. (See figure 6-6.)
1. Remove and retain the two Torx head
screws which secure the dome to the pod. Carefully
remove the dome and set it aside.
2. To gain access to the motor, proceed as
follows:
a. Remove and retain the screws
which secure the pod to the lightbar extrusion.
Remove and retain the screws which secure the
motor support assembly to the pod.
b. Disconnect the six-pin motor
cable plug and the three-pin opto isolator cable.
c. Carefully lift the motor support
assembly from the pod.
3. After servicing is complete, reassemble
the pod by performing the above steps in reverse
order.
6-5. MAINTENANCE.
A. Cleaning the Plastic Domes.
WARNING
Crazing (cracking) of domes will cause reduced
effectiveness of light system. Do not use clean-
ing agents (which will cause crazing) such as
strong detergents, solvents, or petroleum prod-
ucts. If crazing of domes does occur, reliability
of light for emergency purposes may be re-
duced until domes are replaced.
Ordinary cleaning of the plastic domes can
be accomplished by using mild soap and a soft rag.
Should fine scratches or a haze appear on domes,
they can ordinarily be removed with a non-abrasive,
high quality, one-step, automotive paste cleaner/wax
and a soft cloth.
B. Lamp Replacement.
WARNING
A serious injury may result if lamp is touched
when hot. Always allow lamp to cool before
removing.
Figure 6-6. Pod Components.