Bullitt Light Bar Data Sheet

LIGHTBAR GUIDE

Bullitt Basic

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

M001v1.0 Revised November 2017 - 2 -

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


Universal Footpack & Super Strong Magnets

Part No. EM108UF & EM102RFSS

Fixing Style: Temporary


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


Roof Bar Bracket

Part No. EM108RBB


26-56mm bar width with adjustable distance between brackets

Roof Rail Clamps

Part No. EM108RRC

Fixing Style: Semi-Permanent


Universal Footpack & Suction Cups

Part No. EM108UF & EM102SC

Fixing Style: Temporary


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


Roof Rail Bracket

Part No. EM108RRB



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


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



88cm Bullitt Basic BS2 EM312 EBS x1 & EM312 DB8 x1 36 5A




121cm Bullitt Basic BS2 EM312 EBS x2 48 5A




154cm Bullitt Basic BS2 EM312 EBS x2 & EM312 DB8 x1 60 7.5A


171cm Bullitt Basic BS2 EM312 EBS x2 & EM312 DB8 x1 60 7.5A







Dual Colour

Lightbar Size Lightbar Style No. of Controllers No of LEDs Max Current (12v)





















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

Flash Pattern LP Bullitt Spartan DS Flashes (p/m)

1. Mega-Flash 732

2. Quad TA1 (tested amber)

/TB2 (tested blue)

3. Triple TA1/TB2 366

4. Double TA2/TB2 TA1/TB2 TA1/TB2 TA2/TB2 244

5. Single TA1/TB2 122

6. Hyper 480

488

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


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: -

Left Top /

End Section

Middle

Top /

Mid

Section

Right Top /

End Section

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


3.4 E-mail a high-resolution image to support@redtronic.co.uk. This should comprise of a closeup

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 support@redtronic.co.uk

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


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


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: -


Right side

Lightbar LED modules

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

Lightbar LED modules

Left side

3 4

1 2


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


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

Loose

Footpack

Remove and

reapply power to

reset the side

Check all fixings are

secure before

contacting a

Redtronic Support

Team member

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


Bullitt Light Bar Data Sheet

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?