Redtronic Bullitt Basic User manual

LIGHTBAR GUIDE
Bullitt Basic

M001v1.0 Revised November 2017 - 2 -
Contents
1.0
Lightbar Mounting Methods
Page
3
2.0
Lightbar Basic Installation
Page
8
3.0
Lens Replacement
Page
11
4.0
Controller Replacement
Page
14
5.0
Functional Checks
Page
25

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Unpacking
•Check the box for any damage in transit. If the box is damaged, you must report it immediately.
(If the consignment is not signed for as ‘damaged’ it may affect whether the product can be
repaired or replaced free of charge)
•Carefully remove the Lightbar from the box and place it on a flat and stable surface, taking care
not to scratch any of the lenses
•Examine the Lightbar for damage such as cracked or scratched lenses. Report any damage
immediately through Redtronic helpdesk or support
1.0 Lightbar Mounting Methods
Lightbars have several mounting options. These are detailed as follows: -
Universal Footpack
Part No. EM108UF
Fixing Style: Permanent
47-60mm elevation with adjustable angle

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Universal Footpack & Super Strong Magnets
Part No. EM108UF & EM102RFSS
Fixing Style: Temporary
55-68mm elevation with adjustable angle
Dekra speed tested rated to 146mph/235kph)
Can be used in conjunction with a Safety Lanyard (EM173L1)
Universal Footpack & Gutter Mount
Part No. EM108UF & EM108GMUF
Fixing Style: Semi-Permanent

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Roof Bar Bracket
Part No. EM108RBB
Fixing Style: Permanent
26-56mm bar width with adjustable distance between brackets
Roof Rail Clamps
Part No. EM108RRC
Fixing Style: Semi-Permanent

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Universal Footpack & Suction Cups
Part No. EM108UF & EM102SC
Fixing Style: Temporary
55-68mm elevation with adjustable angle
Should be used in conjunction with Safety Lanyard (Part No. EM173L1)
NOTE: Always remove the red caps from suction prior to use –these are for storage only (suction will not work if
caps are present)
M6x25 UNC
Cable Screw

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Roof Rail Bracket
Part No. EM108RRB
Fixing Style: Permanent

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2.0 Lightbar Basic Installation
2.1 Standard Lightbar connectivity: -
N.B. For non-standard Lightbar builds, please refer to ‘Cables’ on page 6 of the Lightbar
Datasheet or to the drawing

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2.2 Fuse: - The following data can be used as a guide to determine the maximum current from standard builds:
(24v vehicles will draw approximately half the current shown in the table below. Installers should contact
their sales representative if they are unfamiliar with fusing requirements)
Single Colour
Lightbar Size
Lightbar Style
No. of Controllers
No of LEDs
Max Current (12v)
55cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
71cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
88cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
88cm
Bullitt Basic BS2
EM312 EBS x1 & EM312 DB8 x1
36
5A
105cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
105cm
Bullitt Basic BS2
EM312 EBS x1 & EM312 DB8 x1
36
5A
121cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
121cm
Bullitt Basic BS2
EM312 EBS x2
48
5A
138cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
138cm
Bullitt Basic BS2
EM312 EBS x2
48
5A
154cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
154cm
Bullitt Basic BS2
EM312 EBS x2 & EM312 DB8 x1
60
7.5A
171cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
171cm
Bullitt Basic BS2
EM312 EBS x2 & EM312 DB8 x1
60
7.5A
187cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
187cm
Bullitt Basic BS2
EM312 EBS x3
72
7.5A
204cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
204cm
Bullitt Basic BS2
EM312 EBS x3
72
7.5A
221cm
Bullitt Basic BS1
EM312 EBS x1
24
2.5A
221cm
Bullitt Basic BS2
EM312 EBS x3 & EM312 DB8 x1
84
10A
Dual Colour
Lightbar Size
Lightbar Style
No. of Controllers
No of LEDs
Max Current (12v)
55cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
71cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
88cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
88cm
Bullitt Basic BS2
EM312 EBS x2 & EM312 DB8 x2
72
10A
105cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
105cm
Bullitt Basic BS2
EM312 EBS x2 & EM312 DB8 x2
72
10A
121cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
121cm
Bullitt Basic BS2
EM312 EBS x4
96
10A
138cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
138cm
Bullitt Basic BS2
EM312 EBS x4
96
10A
154cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
154cm
Bullitt Basic BS2
EM312 EBS x4 & EM312 DB8 x2
120
15A
171cm
Bullitt Basic BS1
EM312 EBS x2
48
5A
171cm
Bullitt Basic BS2
EM312 EBS x4 & EM312 DB8 x2
120
15A
187cm
Bullitt Basic BS1
EM312 EBS x2
48
10A
187cm
Bullitt Basic BS2
EM312 EBS x6
144
15A
204cm
Bullitt Basic BS1
EM312 EBS x2
48
10A
204cm
Bullitt Basic BS2
EM312 EBS x6
144
15A
221cm
Bullitt Basic BS1
EM312 EBS x2
48
10A

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2.3 Flash Pattern: - If the flash patterns are not co-ordinated, i.e. certain banks of LED’s are on different
patterns, you will need to reset all the controllers to their original flash pattern
If you do not have a pattern select switch installed, apply the brown wire from the Bullitt cable to the
positive (+VE) supply on the battery for 2 seconds to reset all controllers to flash pattern 1
If a pattern select switch (momentary) is installed, simply hold the switch down for 2 seconds
Sync; Most Mega-Flash products have been pre-programmed to include a synchronised flash rate.
Products can be synchronised by connecting their yellow cables. All LED’s can be permanently
illuminated (cruise mode) by connecting the yellow cable to negative
If the flash patterns are not co-ordinated, i.e. certain banks of LED’s are on different patterns, you will
need to reset all the controllers to their original flash pattern
Flash Pattern
LP
Bullitt
Spartan
DS
Flashes (p/m)
1. Mega-Flash
732
2. Quad
TA1 (tested amber)
/TB2 (tested blue)
488
3. Triple
TA1/TB2
366
4. Double
TA2/TB2
TA1/TB2
TA1/TB2
TA2/TB2
244
5. Single
TA1/TB2
122
6. Hyper
480

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3.0 Lens Replacement
3.1 Identifying the type of Bullitt Basic Lens required
Firstly, it is necessary to identify the type of lens that has been damaged, which relates primarily to
the size of the Lightbar. The Bullitt range comprises of a number of lens parts and controllers, with
many different colour options, so it is important to know the exact lens required
Example of different lens types: -
There are three methods for identifying which lens has been damaged: -
3.2 Provide a Redtronic support team representative with the serial number on the holographic
label. This is located within the Lightbar, at one end next to the manufacturers inspection sticker or
on the underside, in the centre of the lightbar. It may be necessary to remove the top lens if the
serial number is not clearly visible (see step 3.5 for instructions). Redtronic holds a full description of
your Lightbar, enabling our support team to provide you with the part number relating to a specific
lens
3.3 Measure the Lightbar giving the exact dimensions to a Redtronic support team
representative, explaining precisely where the damage has occurred. From this they will be able to
provide you with the part number(s) required for ordering a replacement lens
Left Top /
End Section
Middle
Top /
Mid
Section
Right Top /
End Section

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3.4 E-mail a high-resolution image to [e-mail]. This should comprise of a close-
up view of the damaged area as well as a distance image showing the entire length of the Lightbar
It may be necessary to return the Lightbar to Redtronic for analysis. Damaged lenses that have been
replaced must be returned to Redtronic in every instance. Please contact [e-mail]
for further assistance
IMPORTANT:
NEVER USE ANY SOLVENTS OR CLEANING PRODUCTS ON THE LIGHTBAR AS THIS WILL CAUSE
DAMAGE TO THE LENSES
3.5 Replacing a top lens
3.5.1 Power off the Lightbar. Remove the top lens of the Lightbar using M6 (5mm) & M4
(3mm) Hex head drill bits or drivers. Remove the M4 hex screws first, then the M6 hex
screws

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3.5.2 Ensure that the LED modules are seated correctly, noting the supporting standoffs
(highlighted below) which are designed to hold the LED module in place
3.5.3 Position the replacement top lens onto the base section of the Lightbar. Make sure
the silicone seal is fitted correctly into the Base section lens
3.5.4 Ensure all LED modules are level with the seating posts in the lens top
3.5.5 Using a drill driver set to torque 1.8Nm, fit the M4x12, M6x25 & M6x12 to secure the lid.
Ensure the drill it is set to ‘driver’ (not ‘drill’ which has no torque setting)
CAUTION! Never tighten any fixings beyond the given torque setting

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4.0 Controller Replacement
If the fault cannot be rectified contact Redtronic for assistance. You will need to provide a Redtronic
support team representative with the serial number on the holographic label. This is located within
the Lightbar, at one end next to the manufacturers inspection sticker or on the underside, in the
centre of the lightbar. It may be necessary to remove the top lens, if the serial number is not clearly
visible (see step 3.5 for instructions). Redtronic holds a full description of your Lightbar, enabling our
support team to provide you with the part number relating to a specific controller or LED module
4.1 Identifying the LED Controller required
It is important to identify the type of controller powering the specific section of the Lightbar that has
failed. The Bullitt range comprises of 2 different controllers, depending on the lightbar specification
Bullitt controller types, showing the 6-way power connector and 2-way LED module connectors: -

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4.2 Diagnosing failure of LED module and / or controller
The controller powers the left and right-side LED modules in the lightbar independently. If all LED
modules have failed, check earth connection from lightbar to the vehicle, secondly check the in-line fuse
between the lightbar cable and the power source. Thirdly, check the positive (+) feed to the lightbar. If
all these tests pass, continue with the steps below
Each LED module leads to one of the sockets on the controller. Where an LED module has failed, that
half of the lightbar module chain will stop working. To identify which LED module has failed, or if the
controller is at fault, unplug the first connector from the faulty side of the controller (no. 1 shown in
diagam below). Unplug a working LED module from the functioning side of the controller and plug an
LED module sequentially through the highlighted sockets (1 to 4) in the diagram –only unplug one
module at a time, then plug it back in when moving to the next socket. When the LED modules on the
faulty side light up, the faulty LED module that was plugged into that socket has been identified. If the
LED module used from the working side to test for the fault doesn’t light up in any of the sockets being
tested, plug all the LED modules from the working side into the sockets being tested for fault. If the LED
modules light up, more than one LED module has failed. If the modules still fail to light, the controller
needs to be replaced. More than one working LED module will be needed in addition to test for more
than one failed module on a chain
Right side
Lightbar LED modules
Left side
Lightbar LED modules
1
2
3
4

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4.4 Replacing the Controller
4.4.1 Power off the Lightbar and remove the lens directly above the controller using M6
(5mm) & M4 (3mm) hex head drill bits or drivers. Remove the M4 hex screws first, then M6
hex screws
4.4.2 Once the top lens has been removed, note down the orientation of the faulty controller
4.4.3 Remove the x4 M3.5x13 screws securing the controller to the base of the Lightbar, using a Pozi
(PZ2) tool
4.4.4 Turn the controller over and note down the LED module connections to the controller
sockets for connection to the replacement controller
4.4.5 Unplug the 6-way connector by pushing inwards on the tabs either side. Remove all
remaining connectors*
*Only ever remove connectors by pulling the cable housing. Never pull on the cable to remove the connector
as this will strain the wires and crimps which will affect connectivity causing further faults
4.4.6 Plug the LED connectors (2-way plugs) into the controller ensuring they go back into
their original locations, as plugging-up incorrectly will affect the flash sequence. Insert the
6-way connector into the controller. The plugs will only fit the controller one way,
easily sliding onto the controller sockets. If you are experiencing difficulty, ensure correct
positioning of the plug. If necessary, check the colour coding of another controller to ensure
this is correct
4.4.7 Once connected, it is important to ensure the tabs of the plugs grip onto the
controller sockets. If a plug moves too easily and is not gripping the socket, vibration will cause
it to become disconnected
4.4.8 Power on the Lightbar. All LED’s should now flash in the correct sequence and cycle
rate. If the patterns need to be set / reset, refer to page 10
4.4.9 Place the controller back into its’ original position. Secure onto the base using the
screws removed earlier. Do not over-tighten as this may cause thread damage
4.4.10 Refit the top lens onto the lightbar. Refer to page 13, section 3.5.2
CAUTION! Never tighten any fixings beyond the given torque setting

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5.0 Functional Checks
Function
Corrective Action
Notes
CAP168
Enabled
(Airport
Mode)
Hold 'Pattern
Select' to +Ve for
10 seconds -
Reverts to ‘Mega-
Flash’
AIRSIDE slow rate, low level
flash pattern. Other flash
patterns are not accessible
when this mode is activated
25% Dim
and 50%
Dim
modes
Hold 'Sync' to -Ve
and momentarily
apply Dim (blue)
cable from Bullitt
10-core to +Ve
Will swap between Bright &
Low Dim
Cruise
Mode
Hold 'Sync' to -Ve
Enables cruise mode (steady
burn / Static On)
Lightbar
Flashes
out of
Sync
Hold 'Pattern
Select' (Brown) for
2 second
Reverts to 'Mega-Flash'
Side
shutdown
Remove and
reapply power to
reset the side
If a lamp is unplugged, then
plugged back in it will not
work. This is not a faulty
controller, it has just shut
down the output
Loose
Footpack
Check all fixings are
secure before
contacting a
Redtronic Support
Team member