Axios LED Lightbar System Program Manual

PDF

Document

1

2

PROGRAM MANUAL CONTENTS

Axios Basics

Understanding Axios user bene its ..................................................................................................................................................

Axios Components & Operation

Getting started with Axios ............................................................................................................................................................... 4

Unpacking the chassis kit ..................................................................................................................................................................

Familiarizing yourself with the chassis ............................................................................................................................................

Axios lightbar features and components ........................................................................................................................................

Preparing the chassis for assembly ................................................................................................................................................... 6

Familiarizing yourself with the keypad controller .......................................................................................................................... 7

Removing the lens .............................................................................................................................................................................

Re-assembling the lens .....................................................................................................................................................................

Familiarizing yourself with the Axios lighting options ...................................................................................................................

Installing the DropLock™ LED Modules

Installing the EZ1401X LED directional module .............................................................................................................................

Test and operate the directional modules

.................................................................................................................................... 10

Installing the EZ1402X LED beacon module ................................................................................................................................... 11

Test and operate the beacon modules

..........................................................................................................................................

Installing the EZ1403WL worklamp module ..................................................................................................................................

Test and operate the worklamp modules

.....................................................................................................................................

Installing the EZ1403AL alley light module .................................................................................................................................... 13

Test and operate the alley light modules

...................................................................................................................................... 13

Installing the EZ1404 LED stop-tail-indicator module ...................................................................................................................

Test and operate the stop-tail-indicator modules

..........................................................................................................................

Installing the EZ1414 Safety Director module ................................................................................................................................

Test and operate the Safety Director module

............................................................................................................................... 15

Configuring Axios

Meeting industry standards .............................................................................................................................................................

Correct module placement ..............................................................................................................................................................

Correct module colors ......................................................................................................................................................................

Correct lash pattern selection ........................................................................................................................................................ 18

Correct labeling ................................................................................................................................................................................ 18

Additional European standards ......................................................................................................................................................

Module positioning guides ..............................................................................................................................................................

Installing Axios

Permanent lightbar mounting ........................................................................................................................................................

Temporary lightbar mounting .........................................................................................................................................................

Wiring to the vehicle ....................................................................................................................................................................... 21

Mounting the keypad controller ..................................................................................................................................................... 21

Figures

Figure 1:

Figure 2:

Figure 3:

Figure 4:

Figure 5:

Figure 6:

Figure 7:

Figure 8:

Figure 9:

Figure 10:

Figure 11:

Figure 12:

Figure 13:

Figure 14:

Figure 16:

Figure 17:

Figure 18:

Figure 19:

Figure 20:

Figure 21:

Chassis kit contents ...............................................................................................................................................4

Chassis features and components ........................................................................................................................5

Wiring diagram .....................................................................................................................................................6

Flash patterns ........................................................................................................................................................6

Keypad controller functions .................................................................................................................................7

Removing the lens ................................................................................................................................................8

Module familiarization .........................................................................................................................................9

Available modules ................................................................................................................................................9

Installing the directional module .......................................................................................................................10

Installing the beacon module .............................................................................................................................11

Installing the worklamp module ........................................................................................................................12

Installing the alley light module .........................................................................................................................13

Installing the stop-tail-indicator module ...........................................................................................................14

Installing the Safety Director module ................................................................................................................15

Industry standards ...............................................................................................................................................

Module placement to meet industry standards .................................................................................................

Compliant module colors ....................................................................................................................................

ECE Regulation 65 enclosure labeling ................................................................................................................

European standards .............................................................................................................................................

Module positioning guide ...................................................................................................................................

Figure 32:

Figure 33:

Permanent mounting ..........................................................................................................................................

Keypad controller mounting ...............................................................................................................................

3

4

AXIOS BASICS

Understanding Axios user benefits

Exclusive DropLock™ technology allows quick and simple twist-lock placement of LED lighting options virtually anywhere in the bar.

Axios now offers customers instant gratification and the opportunity to see, touch, and have direct input on their exact configuration via on-site design and assembly at Axios

Partner stores.

Customers can now get a custom lightbar with little wait time and absolute control of the design. Also, they are able to easily reconfigure or upgrade their bar with additional components at any time. Adding or swapping modules in the DropLock™ power rail requires no tools or technical electronics training, and can be done even once the lightbar is installed on a vehicle. Adding a

SafetyDirector™ requires only simple hand tools.

Axios installation is designed to be easier, too. The chassis kit includes both a CAN bus junction box and keypad controller, which eliminates the need for seperate switches and provides for cleaner cable routing. The keypad makes general operation and flash pattern selection easier too, with large, tactile buttons that provide complete control of all lightbar functions including three convenient flash pattern presets.

The controller also provides visual feedback to the driver of active functions.

When properly configured, Axios lightbars meet SAE Class I,

California Title 13, and ECE Regulation 65.

IMPORTANT:

Buyer should only install, configure, use and operate the Axios Modular LED Lightbar system in a manner that is compliant with all applicable federal, state and local laws, rules and regulations. Such laws, rules and regulations may vary by jurisdiction – and Buyer is responsible for knowing and complying with those that apply to Buyer’s location(s). In particular, careful attention should be payed to the Configuring

Axios section of this Program Manual. ECCO hereby disclaims any and all responsibility and liability with respect to Buyer’s misuse of the

Axios lightbar and the manner in which Buyer elects to configure the lighting elements included with the Axios lightbar. ECCO recommends that only professionally trained and experienced electronics technicians should install the Axios lightbar and/or configure the Axios lighting elements.

AXIOS COMPONENTS & OPERATIONS

The Axios DropLock LED modules and power rail system are designed for simple, quick assembly. The following training sections will help you get familiar with the

Axios components, the basics of building a lightbar and configuring lightbars to meet industry standards.

Getting started with Axios

Each kit features fully solid-state electronics and includes an aluminum chassis, a three or four piece polycarbonate lens assembly (depending on length), a CAN Bus junction box, a keypad controller, and two wiring harnesses

(discrete and STI/Aux/Sync). Chassis kits are available in five lengths: 39”/1m, 48”/1.2m,

54”/1.37m, 60”/1.5m, and 72”/1.8m.

Figure 1: Chassis kit components

48”

lightbar & components example

Unpacking the chassis kit

With the exception of the LED modules, Axios chassis kits are supplied with everything needed to start building a lightbar.

Before adding LED modules, unpack the chassis and place it on a flat surface.

Familiarizing yourself with the chassis

Before attempting to assemble a lightbar for the first time, take a few minutes to study the features and components of the chassis.

Figure 2: Chassis features & components

FRONT

Axios lightbar features and components

Identify the central control board. The control board distributes power and control signals to the DropLock power rails and Safety Director. The logo illuminates when power is applied to the lightbar.

Identify the Safety Director data port on the central control board. This is used to supply power and control signals to the Safety Director.

Identify the Safety Director grommet blank. This notch in the lip of the chassis is used to route the

Safety Director cable into the lightbar. When a Safety

Director is installed, the blank grommet is discarded and replaced with a cable grommet supplied with the Safety Director.

Identify the front and rear of the lightbar. To operate properly, some LED modules must be positioned in a specific orientation. The rear of the lightbar is easily identified as the Safety Director data port on the central control board faces the rear of the lightbar.

Identify the three DropLock power rails. The power rails supply power and control signals to the DropLock lighting modules.

The front and rear power rails are used for beacon and directional warning modules, as well as the stoptail-indicator and center illumination modules.

The center power rail is used for front/ rear worklamps and alley lights.

Identify the module positioning guides.

These markers are intended to assist with the symmetrical placement of modules.

Identify the stop-tail-indicator (STI) data port.

The STI modules must be positioned/connected with this port.

Identify the locking lens latch. These latches secure the lens to the chassis.

5 Preparing the chassis for assembly

In order to check lightbar operation and preset flash patterns during assembly, the lightbar should be wired to a fused power source before beginning. Do not turn on the power source during assembly, only during testing and flash pattern set up. Follow the instructions below and refer to the wiring diagram which describes the function for each wire.

Connect the red, black, blue, and yellow wires from the lightbar to the junction box. Connect a power (red) and ground (black) wire (not supplied) from the junction box to a switched/fused 12VDC power source with a 20A rating. Connect the keypad controller to the junction box.

Disregard the STI/Aux/Sync Harness at this time. If STI modules are included in the lightbar configuration, these wires can be connected to test operation once they are installed (see page

14).

Disregard the Optional Wire Control Harness, this is used for discrete wiring via switches (see page 21).

Figure 3: Wiring diagram

6 Figure 4: Flash patterns

# Description FPM

1 Steady Burn -

SAE T13 R65

CA Title 13 Double

CA Title 13 Slow Quad

CA Title 13 Slow Double

CA Title 13 Quint

Pulse8

R65 Single

R65 Double

R65 Triple

R65 Quad

R65 Burst

R65 Single Side-to-Side

120

R65 Double Side-to-Side

R65 Triple Side-to-Side

R65 Quad Side-to-side

120

R65 Burst Side-to-Side

Quad Alternate Side-to-Side

120

18 Quad Cross Alternate 75

19 Double Alternate Side-to-Side 75

*All R65 flash patterns meet ECE Regulation 65 Class II. Beacon modules meet ECE

Regulation 65 Class I only. All SAE flash patterns meet Class I in day mode and Class II only in night mode.

Double Cross Alternate

Quint Alternate Side-to-Side

22 Quint Cross Alternate

23 Quad Alternate Side-to-Side Front

24 Quad Alternate Side-to-Side Rear

Double Alternate Side-to-Side Front

Double Alternate Side-to-Side Rear

Quint Alternate Side-to-Side Front

28 Quint Alternate Side-to-Side Rear 75

29 Cycle All (2,3,5,6,13,15,16) -

ROTATE MODE (BEACONS ONLY)*

# Description FPM SAE T13

1 R65 Rotate 120

SAFETY DIRECTORS ONLY

# Description

Left

Left Solid

Right

Right Solid

Center Out

Center Out Solid

Wig Wag

Alternating

Alternating Quad Flash

SAE

R65

Familiarizing yourself with the keypad controller

It will be necessary to test/set-up the operation of the modules once the bar is assembled. Before beginning, study the keypad controller and the button explanations below so that you are familiar with its operation in advance.

Figure 5: Keypad controller functions

EZ1405

DAY/NIGHT MODE

When active, it provides backlighting to keypad and lowers intensity of directional modules in the bar.

FLASH PATTERN

INDICATORS

One LED per corner temporarily mimicks warning flash patterns.

CRUISE

Press to illuminate all beacon/ directional modules

(steady burn).

FORWARD

WORKLAMP

Press to illuminate forward worklamps.

AUXILIARY

Control any auxiliary device

(max 20 amp, via relay), not supplied

FLASH PATTERN SELECT

Press to cycle through warning flash patterns.

The keypad will remember the pattern used and store it to the active preset.

ALLEY

LEFT

Press to illuminate left alley light.

ON/OFF SAFETY

DIRECTOR (if equipped)

Will resume last pattern selected.

SAFETY DIRECTOR

FLASH PATTERN

INDICATORS

The 6 LED indicator windows will mimic the flash pattern for realtime feedback.

REAR WORKLAMP

Press to illuminate rear worklamps.

POWER

Press to cycle through three programmable flash pattern presets. Hold button down to shut down all functions. Press again to resume.

SAFETY DIRECTOR

PATTERN SELECT

Press to cycle through Safety

Director patterns.

PRESET 1 PRESET 2 PRESET 3

ALLEY

RIGHT

Press to illuminate right alley light.

7

8 Removing the lens

Locate the lens latch on one end of the lightbar.

Turn the latch 90° counter clockwise to release.

Where the end and mid-section lenses meet, gently press both sides of the end lens inward to release the retaining clips.

Tilt and lift the end lens to remove it from the chassis.

Repeat steps for the other side, and then remove the mid-section lens(es).

Note:

The lens latch can be removed from/attached to the chassis when rotated fully counterclockwise to a downward facing position.

Re-assembling the lens

Refer to this section when the lightbar is fully populated with

LED modules.

Ensure the lens latches are in the open position.

Install one of the end lenses, making sure the lens edge and retaining clips are seated properly. Turn the lens latch 90° clockwise to secure.

Install the mid-section lenses, making sure this lens is completely within the slot on the end lens. For bars with four-piece lenses, install the center baffle and the second mid-section lens in the same manner.

Install the other end lens, making sure the lens edge and clips are seated properly. The mid-section lens must be seated in the slot on the end lens.

Apply gentle downward pressure at each joint to ensure lenses are properly seated in the chassis.

Turn the lens latch 90° clockwise to secure.

Important:

Ensure the lens latches are properly installed and lenses are fully mated with, and secured to the chassis before releasing the lightbar to the customer.

Figure 6: Removing the lens

Retaining Clips

EZ1401X

Directional

Familiarizing yourself with the Axios lighting options

Most modules feature a locking knob on the top that is used to secure the module in the chassis power rail. The directional, worklamp and alley light modules will rotate almost 360° on their bases to maximize placement options within the lightbar. Do not try to over rotate the module past their stops.

Important notes:

• During assembly, ensure the chassis is disconnected from the power source.

• Always stand at the rear of the lightbar during assembly.

• The base of each LED module is marked with a single and a double contact indicator. Care must be taken to ensure proper orientation of the contact indicators for each type of LED module as noted in the following section on module installation.

• The testing of LED modules is included with the instructions for each module in this manual. When configuring your first few lightbars it is suggested that you follow this procedure each time a module is installed.

As you become proficient it will no longer be necessary and the complete lightbar can be populated prior to testing all the modules at one time.

• Each Axios chassis is rated for a maximum of 20 amps of combined current draw from all installed modules

(including Safety Director). Do not install modules in a manner that overloads the junction box.

Module current draw

LED directional =

0.9A Avg. @ 12 VDC

LED beacon =

1.0A Avg. @ 12 VDC

LED STI = 0.3A Avg. @ 12 VDC

LED alley light (pair) = 0.9A Avg. @ 12 VDC

LED worklamp (pair) = 0.9A Avg. @ 12 VDC

LED Safety Director = 2.5A Avg. @ 12 VDC

Top

Base

Locking knob

Double contact indicators Single contact indicator

Figure 8: Available modules

WARNING MODULES

EZ1414

Safety Director

EZ1401X

Directional

AUXILIARY MODULES

EZ1402X

Beacon

EZ1404

Stop-Tail-Indicator

EZ1411-XX

Center Illumination

EZ1403WL

Worklamp

EZ1403AL

Alley Light

9

10

INSTALLING THE DROPLOCK

LED MODULES

Installing the EZ1401X directional module

The EZ1401 LED directional module provides 120º high-intensity warning capability.

Install these modules in the front or rear power rails only.

For correct operation, the single contact indicator on the base of the module must face towards the central control board.

Rotate the top of the module to the desired angle.

To secure the module in the power rail, turn the locking knob clockwise a half turn. Install any additional modules.

To test and and operate the directional modules:

Apply power to the lightbar.

Press the power button on the keypad to turn on the directionals.

Use the SEL and power buttons to set flash pattern presets.

WARNING: Incorrect Installation

Module placed in center power rail: directional will behave like a worklamp and illuminate in steady burn mode and be activated only when both an alley light and worklamp button are on simultaneously. The specific buttons are dependent on where in the bar the module is placed front/rear/left/right).

Contact indicators incorrectly oriented: The operation of alternate and cross alternate flash patterns will be reversed left to right and/ or diagonally. The controller will still reflect correct flash pattern operation.

Figure 9: Installing the directional module

Single Contact Indicator

Ensure the single contact indicator on the base of the module faces towards the central control board.

Refer to page 17 for information on minimum configurations required to meet industry standards.

Single Contact Indicator

Installing the EZ1402X beacon module

The EZ1402 LED beacon module provides 360° warning capability and offers a variety of strobing flash patterns as well as a rotate mode.

Place the two beacon module bases in the front and rear power rails. For correct operation, the beacon module must be oriented so the ECCO logo is legible from rear of lightbar.

To secure the beacon in the power rail, turn both locking knobs clockwise a half turn. Install any additional modules.

To test and operate the beacon modules:

Apply power to the lightbar.

Press the power button on the keypad to turn on the beacons.

Use the SEL and power buttons to set flash pattern presets.

Pressing both alley light buttons simultaneously for two seconds will switch the beacon mode between “flash” and “rotate” modes

WARNING: Incorrect Installation

Both beacons oriented backwards (logo legible from front):

Rotate mode will not operate, however if activated controller will still reflect rotating mode being operational.

One beacon oriented backwards: In addition to above, the beacons will now also alternate left to right on certain

(alternate and cross alternate) flash patterns. Flash pattern behavior is dependent on which beacons are oriented correctly or backwards.

Figure 10: Installing the beacon module

For correct operation, beacon must be oriented so the ECCO logo is legible from rear of lightbar (data port on central control board faces rear of lightbar).

Refer to page

17 for information on minimum configurations required to meet industry standards.

11 Installing the EZ1403WL worklamp module

The EZ1403WL LED worklamp module provides high-intensity scene lighting to the front and/or rear of the vehicle.

For correct operation, modules must be properly oriented using the contact indicators on the base of the module. For rear worklamps, the single contact indicator must face right and for forward worklamps, the single contact indicator must face left when viewed from the rear of the lightbar.

Note:

For the keypad worklamp buttons to function properly, the front facing worklamp must be pointed toward the front and the rear facing worklamp must be pointed toward the rear.

Install the worklamp module base in the center power rail only. The worklamp module is intended for front facing and/or rear facing illumination and should be placed in the locations shown in figure 11.

If necessary, rotate the top of the module to the desired angle.

To secure the module in the power rail, turn the locking knob clockwise a half turn. Install any additional modules.

To test and operate the worklamp modules:

Apply power to the lightbar.

Use the front and rear worklamp buttons on the keypad to operate.

WARNING:

There is a four module maximum load per worklamp button on the keypad. Do not install worklamps in the front or rear power rails as damage to the central control board can occur.

WARNING: Incorrect Installation

Module placed in front or rear power rail: worklamp will flicker when warning modules are powered on, any warning modules installed will either malfunction or not operate.

Contact indicators incorrectly oriented: The operation of the worklamp buttons on the controller will be reversed (front button will turn on rear worklamps and vice versa).

Note:

Although they look the same, worklamp and alley light modules have different electronics and are not interchangeable.

Figure 11: Installing the worklamp module

Double Contact Indicator

12

The worklamp module is intended for front facing and/or rear facing illumination and should be placed in the locations shown above. For correct operation modules must be properly oriented using the contact indicators on the base of the module. For rear worklamps the single contact indicator must face right and for forward worklamps the single contact indicator must face left when viewed from the rear of the lightbar (data port on central control board faces rear of lightbar).

Installing the EZ1403AL alley light module

The EZ1403AL LED alley light module provides a high-intensity spotlight to the left and/or right of the vehicle.

Install the alley light base in the center power rail only. The alley light is intended for side illumination and should be placed only in the location shown.

Position the alley light as close to the end of the bar as possible while ensuring the module remains within the lens enclosure.

If necessary, rotate the top of the module to aim the beam of light as desired. It does not matter which way the contact indicators are facing.

To secure the module in the power rail, turn the locking knob clockwise a half turn. Install any additional modules.

To test and operate the alley light modules:

Apply power to the lightbar.

Use the alley left and right buttons on the keypad to operate.

WARNING:

There is a four module maximum load per alley light button on the keypad. Do not install alley lights in the front or rear power rails as damage to the central control board can occur.

WARNING: Incorrect Installation

Module placed in front or rear power rail: Alley light will be permanently illuminated when power is applied to the lightbar.

Note:

Although they look the same, worklamp and alley light modules have different electronics and are not interchangeable.

Figure 12: Installing the alley light module

The alley light module is intended for side illumination and should be placed in the location shown above.

13 Installing the EZ1404 stop-tail-indicator module

The EZ1404 LED stop-tail-indicator (STI) module enhances the vehicle’s standard position, brake, and turn indicator lighting.These modules provide high-intensity red light to warn other drivers of position and slowing while the turn signal indicator blinks amber.

Install the STI in the rear power rail only.

The STI module can only be placed in one position on each end of the chassis. The connector on the bottom of the module must plug into the STI data port on the chassis as shown.

To secure the STI module in the power rail, turn the locking knob clockwise a half turn. Install additional modules.

To test and operate the stop-tail-indicator modules:

STI modules operate using the vehicle’s existing wiring system. To bench test STI operation, sequentially touch the corresponding wires from the STI/Aux/Sync harness from the junction box to power (see figure 3, page 6).

WARNING:

Take care when installing and ensure the connector is properly seated in the STI data port on the chassis before locking in place. Do not use excessive force. If not seated correctly, damage to the connector and/or the chassis can occur.

Note:

STI modules must be installed in pairs, one at each end of the chassis. When correctly installed STI modules meet the requirements of ECE Regulation 6 and 7.

Figure 13: Installing the stop-tail-indicator module

14

To meet ECE R6 and R7, place one (1) stop-tail-indicator module at each of two (2) allowable rear facing locations with integrated connectors.

Installing the EZ1414 Safety Director™ module

The EZ1414 LED Safety Director is a 30”/762mm long directional warning light designed to direct traffic approaching from the rear of a stationary vehicle.

Required tools: 1/8”/3mm allen key and 3/8”/10mm socket

Attach supplied mounting brackets to the Safety

Director bar as shown below using supplied hardware.

Plug the Safety Director cable into data port on central control board of lightbar as shown. Discard grommet blank from chassis and use grommet that is attached to the Safety Director cable.

Attach Safety Director to lightbar as below using the supplied hardware. Ensure Safety Director is centered properly on the lightbar.

Note:

The Safety Director requires the use of the Axios keypad controller to operate, discrete wiring to switches is not possible.

To test and operate the Safety Director:

Apply power to the lightbar.

Use the Safety Director on/off and pattern select buttons on the keypad to operate

Figure 14: Installing the Safety Director module

Recommended Torque

30in-lb/3.4N-m

Recommended Torque

30in-lb/3.4N-m

14”/356mm - 17”/432mm

Between Brackets, Centered

15

16

CONFIGURING AXIOS

Meeting industry standards

In addition to general lighting industry standards, many regions have adopted specific local requirements for vehicle lighting. ECCO does not provide specific guidance for your local area. It is recommended that you contact your local regulatory authority for this type of information.

In terms of the general industry standards detailed in

Figure 16, the standard that the lightbar needs to meet is typically dictated by where the vehicle is to be operated.

As a rule, ECE Regulation 65 applies to EU member states but has also been adopted by various other countries around the world. Likewise, SAE J845 is primarily applicable in the USA but is also used as the benchmark in various regions around the world. The same is somewhat true of California Title 13 as several other US states have adopted the California standard.

The positioning of beacon and directional warning modules is extremely important to ensure that the assembled lightbar meets the requirements of these industry regulations.

Figure 16: Industry standards

SAE

CLASS

SAE J845 Class I

The Society of Automotive

Engineers (SAE) is an international organization that issues standards and recommended practices for the design, manufacture, maintenance, and operation of equipment for all self-propelled vehicles and related equipment. SAE J845 relates specifically to 360º warning lights and has three class ratings, Class I being the brightest.

ECE

REG

ECE Regulation 65

Mandated by the United Nations

Economic Commission for Europe

(ECE). The ECE establishes laws on a wide range of topics to maintain conformity (and safety) throughout the member states of the European Union. In terms of vehicular legislation alone, there are over

140 different regulations. Regulation 65 relates specifically to warning lights. The regulation has two class ratings, Class II being the brightest.

California Title 13

TITLE

Legislation mandating the standards of vehicle warning lighting in California.

Some, but not all, of the standards evolved from recommendations from

SAE, and other requirements evolved from the California Vehicle Code. Title 13 of the

California Vehicle Code outlines regulations for motor vehicles.

Figure 16: Industry standards

Correct module placement

The correct positioning of warning modules within the lightbar is very simple and is the same for all three of the standards listed in Figure 16. The primary requirement is to ensure the lightbar emits a beam of light that meets specifications for a full 360º around the vehicle. The modules that are intended to satisfy the placement aspect of the standards must be symmetrically placed as close to each end of the lightbar as possible and in the case of directional modules, in each corner at a 45º angle.

The Safety Director module also meets SAE J595 Class I

(when operated on Flash Pattern 8 (alternating) only), this standard is similar to J845 except it relates solely to directional warning devices and does not include the 360º component. The Safety Director will always meet this standard regardless of placeme nt.

Figure 17: Module placement to meet industry standards

10R XX XXXX

1/2

10R XX XXXX

1/2

Minimum configuration to meet SAE Class I,

ECE Regulation 65 and California Title 13.

IMPORTANT:

For lightbars configured with amber directional modules (EZ1401A) and requiring ECE Regulation 65 compliance only. The quantity of directional modules must be limited to 18 or less (maximum 9 to the front and 9 to the rear) to avoid exceeding the regulation’s maximum amber light output requirement.

17

18 Correct module colors

The module colors/types shown in Figure 18 meet the requirements of the corresponding standard. The colors can be mixed provided each of the colors meet the standard. For example a lightbar that is red on one side and blue on the other will still meet the standards, providing a minimum 180º of blue and 180º of red light output.

Note:

Regardless of placement the above modules/colors always meet the light intensity requirements of the regulations, the 360º requirement is only met when the modules are correctly positioned as described on page

17 in the section on correct module placement.

Correct flash pattern selection

Selection of the correct flash pattern(s) is dependent on which standard the lightbar is intended to meet.

Refer to the flash pattern chart on page 6 for information on which patterns meet each regulation.

Tip:

To enable only ECE Regulation 65 flash patterns, press and hold the front and rear worklamp buttons simultaneously for 5 seconds. The keypad flash pattern indicators will flash twice. Repeat this procedure to re-enable all flash patterns.

Correct labeling

The chassis kits and modules are supplied pre-labelled with most of the required compliance markings. Do not remove any pre-applied labels, they are required product markings.

There is one exception: ECE Regulation 65.

ECE Regulation 65 requires a warning light that complies with the standard to be marked as such on the outside of its enclosure. If the light does not comply then it cannot be marked. Therefore, ECCO is unable to supply chassis kits pre-labelled to meet this requirement.

Figure 18: Compliant module colors

SAE

CLASS

ECE

REG

TITLE

Beacons & Directionals

Amber, Blue, Clear/White, Red

Beacons & Directionals

Amber, Blue, Red

Beacons & Directionals

Amber, Blue, Red

In order to comply with the standard, a specific label(s) must be applied during assembly. The required labels are supplied with the chassis kits and can be found inside the plastic bag that contains the Axios User Guide. There are six labels which correspond to both the type and color of modules that meet the ECE Regulation 65 requirement – directional/beacon, amber/blue/red.

The corresponding label need only be applied for those modules that comprise the minimum 360º configuration to meet the standard i.e. the outer modules. Where these modules are comprised of more than one color, labels for each color must be applied.

The label(s) must be applied to the outside of the lightbar enclosure in the location shown in figure 19.

Note:

ECE Regulation 65 does not permit the use of mixed colors within one side of the light bar.

Directionals

Figure 19: ECE Regulation 65 enclosure labeling

ECE

REG

The label(s) must be applied to the outside of the lightbar enclosure in the location(s) shown.

Beacons

Any ECE Regulation 65 labels that are not used must be discarded and not be supplied to the end user.

Figure 18: Compliant module colors

Additional European standards

In addition to the above standards, Axios lightbars and modules also comply with the requirements of several additional regulations as mandated by the ECE.

Figure 20: European standards

ECE

REG

ECE Regulation 6 & 7

These regulations relate specifically to the stoptail-indicator (STI) modules. The regulations govern the performance characteristics of a vehicle’s rear position lights, brake lights, and turn signal (direction indicator) lights. The STI module supplements the vehicles factory installed lighting and is therefore subject to the same standards.

ECE

REG

ECE Regulation 10

This regulation applies to the entire lightbar and relates specifically to electromagnetic compatibility of electronic products fitted to road going vehicles. Meeting this standard signifies that the lightbar emits a minimal amount of electromagnetic interference and therefore won’t “interfere” with other electrical devices on the vehicle. Conversely it also signifies the lightbar is sufficiently protected from electromagnetic interference from other devices.

Module positioning guides

The chassis features module positioning guide markers in between the power rails on both sides. These markers are intended to assist with the symmetrical placement of modules.

The dual marks are 5” apart. Use these guides and the three notches on the base of the directional, worklamp and alley light modules to line up the modules symmetrically both front to rear and side to side.

Tip:

The outermost marker on each end of the lightbar can be used to line up with the outermost notch on the directional module when placing these modules in the corners at 45º. For beacons, align the inside edge of the lens with the first dual mark from the end of the bar.

Figure 21: Module positioning guides

1 2 3

5”

SAFETY

DIRECTOR

19

20

INSTALLING AXIOS

When installing Axios lightbars, always refer to the complete mounting and wiring instructions in the Axios

User Guide, included with every lightbar. This section is intended as an overview only.

Permanent lightbar mounting

Before proceeding with installation, plan all wiring and cable routing. Select the mounting location for the lightbar on a flat, smooth surface and center the unit across the width of the vehicle. The mounting location for the lightbar should be chosen such that the lightbar is level and visibility to approaching traffic is optimized.

Mounting should be such that there is no less than

½”/13mm clearance between the roof and the lightbar at any point. Both the height and angle of the mounting feet can be adjusted slightly, if necessary, using the bolts indicated in figure 32.

edges of the roof where the roof is strongest. Ideally, the outermost holes on the feet should be used for installation. The inner holes on the feet match the hole locations for ECCO 10 and 15 Series lightbars and can be used when one of these lightbars has been previously installed.

Mount the lightbar, with the bolts going through the holes drilled in step 2 (refer to diagram), routing the wire as planned in step 1. See the Wiring section (on page 6) of this manual for further wiring instructions.

Install appropriate washers and nuts and secure the unit. The use of sealing compound is recommended.

Note:

The cable exits the lightbar from the center of the chassis, and can be pressed into the channels on the underside of the chassis to route it toward the left or right of the vehicle.

WARNING:

When drilling into any vehicle surface, make sure that the area is free from any electrical wires, fuel lines, vehicle upholstery, vehicle support members, etc. that could be damaged.

Determine the location of the lightbar and the best route for the wiring.

Determine the position of the mounting feet and drill the 5/16”/8mm - 11/32”/9mm diameter mounting holes accordingly, if needed. The spacing of the mounting feet from left to right is adjustable. It is suggested that the positioning of the feet be symmetrical and near the curved

Temporary lightbar mounting

To avoid drilling into vehicle roofs ECCO offers a range of universal brackets and vehicle model specific gutter strap mounts that are compatible with Axios. Refer to the current

ECCO Product Guide and Price List for specific availability in your region. As many of these straps are vehicle specific, follow the installation instructions included with each kit.

Figure 32: Permanent mounting

Wiring to the vehicle

Before attempting to connect the lightbar wiring harness, refer to the wiring diagram which describes the function for each wire. After the lightbar has been mounted, route the power cable to the junction box (the junction box must be mounted in an interior location). Route a power red wire from the junction box to a fused, ignition-switched power point. Connect a black power wire to a solid ground connection on the vehicle (ideally, directly to the battery negative terminal). Use a fuse according to the wiring diagram. Use cable ties and grommets to secure and protect all cables and wires.

To Use the Keypad Controller

Route the control cable from the junction box to the chosen controller location and connect to the controller.

To Use Switches

Route and connect the wires of the optional wire control harness from the junction box to the battery positive via switches (not supplied). See the wiring diagram wire color/function legend on page 6. Some wires may be unused dependent on specific lightbar configuration.

Wiring the Stop-Tail-Indicator Function

Connect the Tail/Stop/Right/Left wires from the STI/

Aux/Sync wire harness from the junction box to the corresponding wires of the vehicle electrical system.

Wiring the Auxiliary Switch Output

Connect the Brown (Aux Out) wire from the STI/

Aux/Sync wire harness from the junction box to the positive coil of a 12 VDC relay (not supplied).

Connect the negative side of the coil to ground. Run a properly-fused load wire to one contact of the relay

(COMMON). Run a second load wire from the other relay contact (Normally Open) to the Auxiliary device to be powered. Run a ground wire from the other side of the auxiliary device to ground.

Wiring the Sync Function

To synchronize with a second Axios lightbar or device with compatible flash patterns, connect their sync wires (white from the junction box STI/Aux/Sync wire harness) together.

Automatic Power-up Feature

If desired, the Axios lightbar can be wired so that the lightbar automatically powers on the warning modules when the vehicle ignition is switched on.

This feature is only available when the keypad controller is used for operation. Controller operation is only overridden for one second, after which normal operation resumes. The warning lights will remain on until deactivated using the keypad controller.

To activate this feature: Install a jumper wire from either of the flash pattern preset 1 or 2 wires (dependent on which pattern is desired upon automatic power-up) on the Optional Wire

Control Harness to the power terminal on the junction box. If flash pattern preset 3 is desired, connect both flash pattern preset wires to the power terminal. Refer to page 6 for a wiring diagram.

Mounting the keypad controller

The keypad is supplied with three mounting options: a bracket, VHB tape, and hook and loop patch. The rear of the keypad is designed to allow for the cable exit to be routed five different ways to maximize installation locations.

Mount the controller in a location within convenient reach of the operator so that s/he can operate the system without taking their eyes off the road.

Figure 33: Keypad controller mounting

Bracket

BRACKET

Hook & loop patch

HOOK AND LOOP

PATCH

VHB tape

VHB TAPE

Optional accessories

EZ1413-48:

EZ1415:

48’ controller extension cable

Suction cup controller mount

21 MANUFACTURED BY

Hello! I am an AI chatbot specifically trained to assist you with the Axios LED Lightbar System Program Manual. I have thoroughly reviewed the document and can help you locate the exact information you need or explain the content in clear and simple terms. Whether you're looking for guidance on specific features, troubleshooting steps, or general usage, feel free to ask your questions. The more details you provide about your concerns or needs, the more accurately and effectively I can assist you!

Assistant typing

Assistant is out of keyboard. Please, try again later.

It looks like you'''ve reached a document that is written in multiple languages, including one that isn''t your native language. You can use the following links to temporarily hide pages without the language you prefer.