Code 3 XP 9500 - Manual (Page 4)

4
This Product contains high intensity LED devices. To prevent eye damage, DO NOT stare
into light beam at close range.
WARNING!
!
LED Fusing Considerations
Although the average current draw per module is very low, due to the type of circuit used to power
each module, the instantaneous peak current to a module can be significantly higher during low
voltage conditions. To avoid prematurely blowing ATO style fuses or tripping breakers, it is
recommended the following rule-of-thumb be used to size fuses or breakers. This is especially
important in lightbars with many LED modules running off a single fused source.
Minimum fuse size calculation:
1.5 x (number of 6/8/12-up modules being fused) + .5 x (number of 3-up modules being fused)
Example:
XP9500 lightbar with 7 forward facing 6-up modules and 16 angled and end facing 3-up modules
Minimum fuse requirement for single fuse: (1.5 x 7) + (.5 x 16) = 18.5A minimum
Note:
Each 35 Watt halogen lamp requires 3A fusing. Each 55 Watt halogen lamp requires 5A fusing.
LED Warning Devices
Wiring Instructions
Larger wires and tight connections will provide longer service life for components. For high current wires it
is highly recommended that terminal blocks or soldered connections be used with shrink tubing to protect
the connections. Do not use insulation displacement connectors (e.g. 3M
® Scotchlock type connectors).
Route wiring using grommets and sealant when passing through compartment walls. Minimize the number
of splices to reduce voltage drop. High ambient temperatures (e.g. underhood) will significantly reduce the
current carrying capacity of wires, fuses, and circuit breakers. Use "SXL" type wire in engine compartment.
All wiring should conform to the minimum wire size and other recommendations of the manufacturer and be
protected from moving parts and hot surfaces. Looms, grommets, cable ties, and similar installation
hardware should be used to anchor and protect all wiring. Fuses or circuit breakers should be located as
close to the power takeoff points as possible and properly sized to protect the wiring and devices. Particular
attention should be paid to the location and method of making electrical connections and splices to protect
these points from corrosion and loss of conductivity. Ground terminations should only be made to
substantial chassis components, preferably directly to the vehicle battery. The user should install a fuse
sized to approximately 125% of the maximum Amp capacity in the supply line to protect against short
circuits. For example, a 30 Amp fuse should carry a maximum of 24 Amps. DO NOT USE 1/4" DIAMETER
GLASS FUSES AS THEY ARE NOT SUITABLE FOR CONTINUOUS DUTY IN SIZES ABOVE 15 AMPS.
Circuit breakers are very sensitive to high temperatures and will "false trip" when mounted in hot environ-
ments or operated close to their capacity.
WARNING!
!
Always refer to the wire tag attached to the lightbar cable to match lightbar functions with colored
wire. Several items may be controlled by the same wire. Extend all control wires to switching
device and make appropriate connections. The black ground wire must be securely attached to the
vehicle chassis to provide reliable grounding.