Carson Manufacturing Co., Inc.
5451 North Rural Street
Indianapolis, IN 46220
Phone: (888) 577-6877 Fax: (317) 254-2667
TECHNICAL BULLETIN
P.A. VOLUME
MAN WAIL
SIREN
YELP
PHASER
HORN
RADIO
HI
LO
ON
OFF
SA400
INSTALLATION AND
OPERATING MANUAL
SA-400-63 14V
SA-400-63 28V
SA-400-63 PG (Positive GND)
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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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".
May need to set RADIO VOLUME ADJUST inside the unit before final mounting and installation
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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ELECTRICAL CONNECTIONS
Disconnect vehicle battery before making any electrical connections.
Electrical connections to the amplifier are made using the wiring harness supplied. If the amplifier needs service the
connector can be easily removed without unwiring the harness. The power supply for the amplifier 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. A fuse on the unit protects from overload.
Wire Size and Termination - The diagram shows the minimum wire size used for each connection. 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.
Negative Connection (Black) - Both leads must be used. Connect to negative battery connector or high current
buss.
Positive Connection (Red) - Both leads must be used. Connect to positive battery connector or high current buss. A
power relay may be used.
Speaker Connection (Brown) - Both leads must be used. Connect 1 lead to each terminal or lead of the speaker.
When used with 2 speakers connect each brown lead to both speaker terminals or leads (parallel circuit). Observe
polarity (phasing) when connecting 2 speakers.
Optional Radio Input Connection (Blue) - Connect 1 lead to each terminal of the radio speaker or output connector.
The input is isolated and polarity is not important. May need to set RADIO VOLUME ADJUST inside the unit.
Optional Auxiliary Input Connection (White) - The Auxiliary Input allows an external source to activate the Siren
push button function. The diagram shows a horn ring connection example. Activated by positive or negative input.
NOTE: Permanent disconnection of the vehicle horn is NOT recommended.
#14 AWG RED
Use both leads
Extend with #12
+
BAT
-
#14 AWG BLK
Use both leads
Extend with #12
(2) #18 AWG BRN
(#16 - 2 SPKR)
2 - SPKR - Connect for
Added
SPDT
Switch
same phase (+ to +)
RADIO
CP2560
HORN
CABLE
(2) #18 AWG BLU
Connect to output
jack, terminals or
speaker of radio
RING
SWITCH
HORN
AUX
AUX
#18 AWG WHT
HORN RING
CONNECTION
WIRING HARNESS CONNECTIONS
BLACK TO -VDC
WHITE TO AUX
SIREN SWITCH
BLUE TO TWO WAY
RADIO SPKR
RED TO +VDC
BROWN TO SPKR
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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)
P.A. VOLUME
MAN WAIL
SIREN
YELP
PHASER
HORN
RADIO
HI
LO
ON
OFF
SA400
The OFF/ON Toggle 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:
RADIO -
This mode reproduces, or repeats, the output of a radio. The radio must be connected and
RADIO VOLUME ADJUSTed for this mode to function. No overrides available in this mode.
HORN -
MAN -
Also considered a standby mode. Horn and PA Override available in this mode.
The siren tone is controlled Manually with SIREN button. PA Override available in this mode.
WAIL -
The siren produces a normal rise-fall tone pattern. This mode should be used on highways or
areas with constant traffic flow. Yelp and PA Override available in this mode.
YELP -
The siren produces a moderate warble tone. This mode should be used in lightly congested
areas. Horn and PA Override available in this mode.
PHASER -
The siren produces a very fast warble tone. This mode should be used at intersections or in
highly congested areas. Horn and PA Override available in this mode.
OVERRIDE FUNCTIONS
PUBLIC ADDRESS
(PA) OVERRIDE -
By pressing the microphone button any siren tone output is turned off, allowing the operator to
use the siren as a public address amplifier. The siren tone resumes when the button is
released. (Hold the microphone close to your lips for proper operation and adjust the PA
VOLume Control)
HORN OVERRIDE -
By pressing the SIREN button the siren tone output is replaced by the horn tone. The siren
tone resumes when the button is released. (This feature is not available in WAIL mode.)
YELP OVERRIDE -
Available only in WAIL mode. By momentarily pressing the SIREN button the tone output is
switched to the Yelp tone. Pressing the button again switches the tone output back to Wail.
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RADIO VOLUME ADJUST
The RADIO VOLUME ADJUST is a one time setting which depends on the radio connected and its normal volume.
The siren cover must be removed to access the adjustment. The cover is held in place by a snap-fastener on the back
of the unit. While holding the case on the sides press hard with your fingers on the back of the unit. The chassis will
slide out the front.
Switch siren to RADIO mode and turn on the power. With the volume on the radio itself set to normal level, set the
RADIO VOLUME ADJUST to the desired level. Turn off power and press the chassis back into the cover.
REMOVE COVER
RADIO VOLUME ADJUST
(ON P.C. BOARD)
58/80
100
3AG FAST ACTING FUSE
20AMP (SA-400-63 14,PG)
10AMP (SA-400-63 28)
POWER OUTPUT SWITCH
(INSIDE SIREN ON CHASSIS)
POWER OUTPUT ADJUST
The POWER OUTPUT adjustment is a one time setting which depends on the speaker(s) used.
The siren cover must be removed as described above to access the adjustment.
For 58W or 80W speaker(s), set the POWER OUTPUT SWITCH TO “58/80”.
For 100W speaker(s) set the POWER OUTPUT SWITCH to “100”.
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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) 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 siren emits a 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 Siren Pushbutton Light come on?
Do you hear a “pop” when turned on?
With siren on, yelp selected, listen for tone in
amplifier.
Connector or connections loose
Internal fuse blown
Loose connection at power source Is an external fuse or circuit breaker used?
Are the power leads connected to a good buss?
No siren tone –
PA works
No PA
High Voltage Protection
Mic Button stuck
The input voltage must be less than highest rating.
Does Mic Button release properly?
Try turning the PA volume control.
PA is not available in 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?
PA volume not set properly
Function switch in Radio
Speaker assembly loose
Intermittent Aux Input connection
Low Vehicle voltage
Distorted siren sound
Intermittent siren tone
High Voltage Protection
Connector 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 stuck on Siren switch stuck
Aux Input improperly connected
Does the Siren pushbutton switch return fully when
released?
Is the Aux Input used and wired properly?
Is the radio connected properly to the unit?
Can you hear the radio in the vehicle?
Try adjusting the internal radio volume control.
No Radio
Unit not connected to a radio
Radio volume too low
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.
TB0321B
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PARTS
5
6
P.A. VOLUME
MAN WAIL
SIREN
YELP
PHASER
HORN
RADIO
2
4
HI
LO
4
8
ON
OFF
SA400
7
3
1
9
Item Part #
Description
CP3966
CP3571
CP2602
CP2560
CP2856
ES00004-04
658-214L
CP3448
CM7382
CM7327
M-20
Bolt, mounting, 1/4-20 X 3/8 (2 required)
Bracket, mounting
Cable, internal chassis plug wiring harness
Cable, external wiring harness
Control, PA volume (350 ohm)
Cover with spring retainer
Knob, rotary function switch and PA volume control (replace with CP4852 Knob)
Label, front panel for SA-400-63
Lamp, T-1-3/4 14V Bi-pin (Chicago Miniature Lamp, Inc. #7382) (used on SA-400-63 14,PG)
Lamp, T-1-3/4 28V Bi-pin (Chicago Miniature Lamp, Inc. #7327) (used on SA-400-63 28)
Microphone with preamplifier
1
2
3
4
5
CP3633
ES00004-06
2FA53-73
CP2744
2N5884
Microphone clip with mounting screws
Switch, pushbutton assembly siren (Switch alone is Switchcraft #LUS001, Cap #P2349-1)
Switch, toggle power (Carling Switch #2FA53-73)
Switch, rotary function
Transistor, output (2 required) (Motorola #2N5884 or Carson #CP2742)
6
7
8
9
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