Carson SA 500 10 28V User Manual

Carson Manufacturing Co., Inc.  
5451 North Rural Street  
Indianapolis, IN 46220  
Phone: (888) 577-6877 Fax: (317) 254-2667  
TECHNICAL BULLETIN  
VOLUME  
SA-500  
YELP  
WAIL  
MAN/PHSR  
HORN  
RAD  
PA  
STBY  
O
RADIO  
O
F
N
F
INSTALLATION AND  
OPERATING MANUAL  
SA-500-10 14V  
SA-500-10 28V  
Carson is a trademark of Carson Manufacturing Company, Inc.  
Sound Hazard - Sound level from siren speaker (>120dBA @ 10 feet) may cause hearing damage.  
Do not operate siren without adequate hearing protection for you and anyone in immediate vicinity.  
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)  
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09/27/05  
INSTALLATION  
Proper installation of the unit is essential for years of safe, reliable operation. Please read all instruction before  
installing the unit. Failure to follow these instructions can cause serious damage to the unit or vehicle and may void  
warranties.  
SAFETY PRECAUTIONS  
For the safety of the installer, vehicle operator, passengers and the community please observe the following safety  
precautions. Failure to follow all safety precautions and instructions may result in property damage, injury or  
death.  
Qualifications - The installer must have a firm knowledge of basic electricity, vehicle electrical systems and  
emergency equipment.  
Sound Hazard - Sound level from siren speaker (>120dBA @ 10 feet) may cause hearing damage.  
Do not operate siren without adequate hearing protection for you and anyone in immediate vicinity.  
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)  
Mounting - Mount the unit for easy access by the vehicle operator. DO NOT mount in air bag deployment area.  
Assure clearances before drilling in vehicle. To prevent internal damage mounting bolts must not enter case more  
than 1/4".  
Wiring - Use wiring capable of handling the current required. Make sure all connections are tight. Route wiring to  
prevent wear, overheating and interference with air bag deployment. Install and check all wiring before connection to  
vehicle battery.  
Testing - Test all siren functions after installation to assure proper operation. Test vehicle operation to assure no  
damage to vehicle.  
Keep These Instructions - Keep these instructions in the vehicle or other safe place for future reference. Advise the  
vehicle operator of the location.  
MOUNTING  
The mounting bracket supplied can be installed above or below the unit. Choose a mounting location convenient to  
the operator and away from any air bag deployment areas. Inspect behind mounting area for clearance. Assure  
adequate ventilation to prevent overheating. Consider wire routing and access to connections, as well as microphone  
bracket placement. Install mounting bracket to vehicle using 1/4" hardware (not supplied).  
If mounting in a rack or console, make sure that mounting bolts do not enter case more than 1/4".  
A microphone clip along with mounting screws (CP3633) holds the microphone in place.  
CP3571 Mounting Bracket  
1/4-20 Bolt  
(CP3966)  
Bolt must not pass through  
cover more than 1/4”  
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09/27/05  
INSTALLER-SELECTABLE OPTIONS  
Carefully cutting programming resistor jumpers or traces on the printed circuit  
board inside the case can select various options. The cover must be removed  
to access the jumpers. The cover is held in place by a snap-fastener on the  
back of the unit. Hold the unit with the front case flange on the edge of a hard  
surface and press hard on the back of the unit. The chassis will slide out the  
front of the cover.  
FUSE  
OPTION JUMPERS  
Auxiliary Input Function - The auxiliary input normally activates the Horn  
function. To activate the Man/Phsr function with the auxiliary input cut the  
jumper resistor labeled "AUX I".  
Auxiliary Input Polarity - The auxiliary input is normally activated by connecting to positive. To activate by  
connecting to ground cut the two jumper resistors labeled "AUX P".  
Cutout Input Polarity - The cutout input is normally activated by connecting to positive. To activate by connecting to  
ground cut the two jumper resistors labeled "CUT P".  
Two-Tone - Two-Tone can replace Phaser by cutting the jumper resistor labeled "T-T".  
Phaser Disable - The Phaser function can be completely disabled by cutting the jumper resistor labeled "PHSR".  
Horn Ring Cycler option (HRC) - This option allows selection of Wail, Yelp, Phaser and Standby by repeatedly  
pressing horn ring or other switch connected to the auxiliary input. It is selected by cutting both the "AUX I" and  
"PHSR" jumper resistors. This disables Phaser operation in the Wail or Yelp positions  
Horn Disable - The Horn function can b e disabled by cutting the trace on the back of the  
board at the location designated "cut to disable horn".  
Cut to  
Disable horn  
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09/27/05  
ELECTRICAL CONNECTIONS  
Disconnect vehicle battery before making any electrical connections.  
Electrical connections to the unit are made using a  
removable terminal block plug located on the back. A  
label on the unit identifies the terminal function. You  
(2) #22 AWG BLU  
Connect to output  
jack, ter mi nals or  
speaker of r adi o  
#22 AWG WHT (See below)  
#22 AWG GRN ( See bel ow)  
should install the connector on the unit before wiring. If  
the unit needs service the connector can be easily  
(2) #18 AWG BRN  
(#16 - 2 SPKR)  
2 - SPKR - C onnect for  
#14 AWG R ED  
Use second lead  
for 2 - SPKR  
RADIO  
removed without unwiring the connector.  
same phase (+ to +)  
The power supply of the unit must be capable of  
delivering peak currents up to 50 amps for adequate  
short circuit protection and reliable operation. The  
preferred source is directly at the vehicle battery. The  
unit is internally fused.  
+
BAT  
-
#14 AWG BLK  
Use second lead  
for 2 - SPKR  
Attach leads by stripping 3/8", inserting into connector  
••••••••••  
and clamp by tightening screw. Make sure the screw is  
tight and the wire can't be pulled out. Failure to  
adequately tighten the screw can result in improper  
operation or burning the connector and wire.  
Wire Size and Termination - The diagram shows the  
minimum wire size used for each connection, along with  
recommended lead color. If the wire is longer than 10 ft.  
use the next larger wire size. Use only high quality  
crimp connectors for installation on the vehicle.  
CONNECTIONS AT REAR OF UNIT WITH  
CP4688-10 POWER CONNECTOR (10-Pin)  
Header  
10-P Terminal Block Plug (CP4688-10)  
Install with screw terminals face down  
Auxiliary Input Connection - The Auxiliary  
Input allows activation by an external source  
of either the Horn or Man/Phsr function. The  
adjacent diagram shows three connection  
+VDC  
+VDC  
MOMENTARY  
FOOT  
SWITCH  
Added  
SPDT  
Switch  
HORN  
RING  
SWITCH  
HORN  
RING  
SWITCH  
HORN  
SPLIC E  
AUX  
examples.  
SELECTABLE  
See  
OPTIONS  
the  
INSTALLER-  
section for  
HORN  
programming details.  
NOTE: Permanent disconnection of the  
vehicle horn is NOT recommended.  
-VDC  
switching  
example  
Must cut AUX P  
option resistors  
AUX  
AUX  
+VDC Switching examples  
+VDC  
ADDED  
DOOR  
SWITCH  
SPLIC E  
DOOR  
DOME  
LIGHT  
SWITCH  
Cutout Input Connection - The Cutout Input turns off any siren  
tone output when activated, and remains off until a control is  
activated or changed. The adjacent diagram shows two connection  
examples. See the INSTALLER-SELECTABLE OPTIONS section  
for programming details.  
CUT  
CUT  
-VDC  
switching  
example  
Must cut CUT P  
option resistors  
+VDC Switching  
example  
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09/27/05  
OPERATION  
Sound Hazard - Sound level from siren speaker (>120dBA @ 10 feet) may cause hearing damage.  
Do not operate siren without adequate hearing protection for you and anyone in immediate vicinity.  
(Ref. OSHA 1910.95 for occupational noise exposure guidelines)  
The OFF/ON Rocker Power Switch controls the siren power. The siren may be left on any time the vehicle is in  
operation. The power should be turned off when vehicle is not being used to conserve battery power.  
The Rotary Function Switch selects various operating modes. These modes are as follows:  
Yelp:  
Wail:  
The siren produces a moderate warble tone. This mode may be used in  
lightly congested areas.  
YELP  
WAIL  
The siren produces a normal rise-fall tone pattern. This mode may be  
used on highways or areas with constant traffic flow.  
STBY  
RADIO  
Standby: A silent mode that allows Manual, Horn and Public Address operation.  
Radio:  
This mode reproduces, or repeats, the output of a radio. The radio must be connected and RADIO  
VOLUME on the face adjusted. No siren tones or PA operation are available in this position.  
Manual /  
Phaser:  
With the mode switch in the Standby position this push-button switch  
provides Manual siren tone control, rising when pressed and falling when  
released. When the mode switch is in the Yelp or Wail positions, the  
push-button provides Phaser tone. This tone is a very fast warble tone  
used at intersections or in highly congested areas. Pressing the button  
once changes to the Phaser tone and pressing again changes the tone  
back to Yelp or Wail. Optional operation includes replacement of the  
Phaser tone with Two-Tone or disabling the Phaser tone entirely  
MAN/PHSR  
HORN  
Horn:  
PA:  
This push-button switch provides a simulated air-horn tone while pressed. This can be used to  
supplement the normal vehicle horn and is useful at intersections or in low noise areas. This tone will  
override all other siren tones.  
Pressing the microphone button in any mode except Radio changes the unit to PA (Public Address). The  
siren mode resumes when the button is released. Adjust the PA Volume and hold the microphone close  
to your lips for proper operation.  
Volume Controls  
VOLUME  
Volume controls are provided for radio repeat function volume and public address volume.  
These should be set when the vehicle is parked. Set the RAD volume with the selector switch  
in the Radio position and the radio volume set to desired level. Set the PA volume to the  
maximum level with no feedback (squeal).  
RAD  
PA  
Auxiliary Input  
During installation an auxiliary input may be connected to the horn ring or other switching device. It provides the same  
operation as pressing the Horn button or optionally the Man/Phsr button.  
Cutout  
During installation a cutout input may be connected to a door switch. It turns off any siren tone when the door is  
opened. The siren tone will continue to be cut off even when the door is closed. Changing any siren control switch or  
input will restore normal function.  
Horn Ring Cycler (Optional)  
During installation, the auxiliary input may be connected to the horn ring or other switching device, and the HRC option  
programmed. With the mode switch set to the Standby position, the horn ring can be pressed repeatedly to select the  
Wail, Yelp, Phaser and Standby tones or modes in succession. Operating any other switch resumes normal  
operation. Please note that this option disables Phaser selection in the Wail or Yelp selector switch positions.  
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Page 6 of 8  
09/27/05  
SERVICE  
This unit is designed to provide years of reliable service under even the worst conditions. Many times there may  
appear to be a problem with the unit when the true problem is in the speaker(s), controlled devices, or improper  
installation. The following chart shows typical symptoms and possible causes.  
A blown internal fuse doesn't necessarily mean that the unit is bad. If a speaker or speaker lead is shorted this fuse  
will blow before the unit is damaged. Disconnect the SPKR leads and replace the fuse. If the unit itself emits a low  
level sound when in the Yelp position it is OK. Check the speaker(s) or leads for possible shorting.  
PROBLEMS  
Symptom  
Possible Cause  
Check  
No Power or siren output Power switch not turned on  
Bad Speaker  
Does backlighting come on?  
Do you hear a “pop” when turned on?  
With siren on, yelp selected, listen for tone in amplifier.  
Is an external fuse or circuit breaker used?  
Connector or connections loose  
Internal siren fuse blown  
Loose connection at power source Are the power leads connected to a good buss?  
No siren tone –  
PA works  
High Voltage Protection  
Mic button stuck  
The input voltage must be less than highest rating.  
Does mic button release properly?  
Cutout activated  
Does siren work when Cutout input is disconnected?  
Is the CUT P option properly configured?  
Try turning the PA volume control.  
PA is not available in the Radio position.  
Is the speaker bell or tip loose?  
Is the Aux Input used and wired properly?  
The input voltage must be greater than lowest rating.  
Is the vehicle voltage regulator working properly?  
Is the connector tight on the back of the unit?  
Cutout Polarity Option set wrong  
PA volume not set properly  
Selector in Radio position  
Speaker assembly loose  
Intermittent Aux Input connection  
Low vehicle voltage  
No PA  
Distorted siren sound  
Intermittent siren tone  
High Voltage Protection  
Connector or connections loose  
Loose connection at power source Check for loose leads back to power source.  
Mic button activation  
Circuit breaker in supply  
connection  
Is something lying on the microphone?  
Is a circuit breaker used with at least 50A rating?  
Horn or Manual or  
Phaser stuck on  
Horn switch stuck  
Does the Horn switch return fully when released?  
Does the Man/Phsr switch return fully when released?  
Is the Aux Input used and wired properly?  
Man/Phsr switch stuck  
Aux Input improperly connected  
Aux Input Polarity Option set  
wrong  
Is the AUX P option properly configured?  
No Radio  
Unit not connected to a radio  
Radio volume too low  
Is the radio connected properly to the unit?  
Can you hear the radio in the vehicle?  
Try turning the RAD volume control.  
Is the T-T option jumper cut?  
Is the AUX I option jumper configured properly?  
Is the PHSR option jumper cut?  
Wrong siren tone  
Two-Tone option installed.  
Aux Input set to wrong function  
Phaser disabled  
Phaser not working  
Horn not working  
Horn disabled  
Is the trace cut that disables the Horn switch?  
RETURN  
If you have any questions concerning this or any other Carson product, please contact our Technical Service  
Department at (888) 577-6877. Many issues can be handled over the phone. We can also be reached via e-mail at  
If a product must be returned for any reason, please contact our Technical Service Department to obtain a Returned  
Merchandise Authorization number (RMA#) before you ship the product to Carson. Please write the RMA# clearly on  
the package near the mailing label. Be sure to provide a return address, contact and phone number, along with a brief  
description of the problem.  
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Page 7 of 8  
09/27/05  
PARTS  
6
10  
1
8
4
VOLUME  
SA-500  
YELP  
WAIL  
MAN/PHSR  
HORN  
RAD  
PA  
STBY  
O
F
RADIO  
O
N
F
7
9
2
5
11  
3
Item Part #  
CP3966  
Description  
Bolt, mounting, 1/4-20 X 3/8 (2 required)  
Bracket, mounting  
CP3571  
1
2
3
4
5
CP4686  
Button, white (for pushbutton switch) (substitute CP4837 red button)  
Connector, 10-P header  
Connector, 10-P terminal block plug  
Control, volume, PA or RAD (1K ohm)  
Cover with stud (does not include CP4679 Chassis)  
Fuse, 20A Automotive (SA-500-10 14)  
Fuse, 10A Automotive (SA-500-10 28)  
Knob, rotary switch black, (substitute CP4852 black knob)  
Label, front panel  
CP4687-10  
CP4688-10  
CP4684  
CP4680-1  
ATO/ATC 20A  
ATO/ATC 10A  
CP4702  
6
7
CP4835  
CP3570  
Microphone, Noise Canceling  
CP3633  
SR-15-1  
Microphone clip with mounting screws  
Microphone strain relief  
8
9
CP4685  
CP3962  
Switch, pushbutton, Horn or Man/Phsr  
Switch, rocker power  
10  
11  
CP4683  
CP4119  
Switch, rotary function  
Transistor, output (2 required) (Industry standard TIP36C, Not Texas Instruments)  
ED1558  
Kit, Hardware (includes CP3966 bolts, CP4688-10 connector, CP3633 mic clip)  
TB0353A  
Page 8 of 8  
09/27/05  

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