Warning/Hazard Lighting MASTERY STATEMENT:

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1 GROTE TRAINING SERIES Warning/Hazard Lighting MASTERY STATEMENT: In this module you will learn and understand the different types of warning/hazard lighting offered in the industry. Warning/Hazard Lighting...2 Fleets that use Warning / Emergency Devices...2 Specifications...3 Regulations...3 Warning/Hazard Lamps...4 Types of Warning/Hazard Lights...5 Other Types of Warning/Hazard Devices...6 Popular Grote Products by Type of Light...7 Additional Resources...16

2 WARNING/HAZARD LIGHTING Segment Overview The Warning and Hazard lighting segment should not be overlooked during lighting discussions. Like all other vehicle lighting, Warning and Hazard lighting requirements are regulated from region to region and state to state. It is very important that our sales representatives know the specifics of a given application as well as the pertinent regulations that govern that application. In this way we can provide the proper lamp, ensure regulatory compliance, and help provide the best possible solution for the specific application and needs for of the customer. Upon completion of this segment you will have the knowledge and confidence with which to sell warning lights. This segment will cover: the fleets that buy this product how this segment goes to market industry regulations the fleets that require specifications for warning lights the different types of warning light categories and what makes them unique. Key Points Warning and Hazard lighting requirements are regulated from region to region and state to state. FLEETS THAT USE WARNING AND HAZARD DEVICES Many different types of vehicles are equipped with warning lights, from cars and trucks, to semi s and fork lifts. They are usually part of a fleet of vehicles tied to a specific industry. The most common of these industry fleets are: Utility Road Maintenance Vehicles Waste Management Construction Warehousing : Forklifts and on-site equipment Government Department of Roads Police Fire Ambulance Snow plow trucks Escort companies ( Wide Loads) Agriculture Mining Oil and Gas fields Towing Volunteer Fire and Rescue Operations Logging School Buses Our primary focus is on the Amber lighting segment of the business. Amber lighting is used to warn of a potential hazard or danger. The Red-and Blue lighting segment, (Police, Fire and Ambulance) is a very technical and highly customized segment. Red-and-Blue lighting is used to denote emergency situations i.e., life and death situations where speed and time are of critical importance Key Points Amber lighting is used to warn of a potential hazard or danger. Redand-Blue lighting is used to denote emergency situations 2

3 SPECIFICATIONS More than other segments, with Warning/Hazard light sales, government agencies will review product and decide what they want to purchase. Then they will write a Specification on the product they want to acquire. The reason they write a Specification is because they have to put a request for quotes out to the public. When this happens, they want to make sure they get the product they intended to buy. If the Specification is not written well enough, they may have to take another product that they did not intend to buy, or they can throw the bid out. An example of a specification would be: Strobe Light The product must be 5 inches in diameter, 6 inches tall, lens should be amber in color and made out of Lexan. The electronics shall be potted in epoxy with the smart technology feature for the flashes. The strobe tube shall be a xenon gas strobe tube. The light shall meet SAE J845 and be a Class 1 warning light. Reference Grote part number If a specific product is not specified, it is important that we educate governmental agencies on the differences in the product and provide them with specific application examples. For example, if a company is looking for a forklift warning lamp on a machine that is only going to be used indoors as needed. They may be able to use a plastic base, non- potted, less expensive lamp. However, if the user is looking for a forklift warning device on a machine that is going to be used outside and exposed to the elements, they should consider a fully-potted, more ruggedly constructed device for this application to ensure on-going performance and reduced replacement costs. Familiarize yourself with the descriptions and technical info on the products. Check that we are clearly stating when a product should be vibration resistant or can stand up to heavy vibration and road shock. As in all cases, the right product for the application is the best decision from a cost performance point of view over the long run. REGULATIONS There are no Federal Regulations that cover the use of Warning/Hazard lamps. Therefore, the lack of federal regulations makes it important that you know the regulations for the state you are in. Most states have statutes regulating the use of Warning/Hazard lamps, and some municipalities call out specifications as well. There is no requirement that a warning lamp utilize a particular type of light source. Vehicles required or authorized to use Warning/Hazard signal lamps choose the lamps best suited for their application based on the requirements of their state or municipality. Then those lamps would be certified to the appropriate SAE standard and the appropriate Class for the vehicle. SAE Standards (Society of Automotive Engineers) set the requirements for Emergency Vehicle lighting. Products are usually specified to the SAE standards for the application in which they are being placed. Regulations such as GSA KKK-A-1822F (U.S. General Services Administration) and NFPA 1901 (National Fire Protection Association) provide requirements for warning lamps on Emergency Vehicles. Key Points Due to requirements, Government agencies will review product and decide what they want to purchase then write a spec on the product. Then a request for quote is created. Key Points Regulations for Warning and Hazard lamps is the responsibility of each state. It is important that the states regulations and requirements are understood in order to provide accurate information on these items. 3

4 WARNING/HAZARD LAMPS The basic definition of Warning/Hazard lamps: Lamps that are mounted on vehicles which, when flashing, inform other drivers of a situation where caution is needed. There are 3 types of SAE Standards for Warning/Hazard lamps: 1. Directional Warning Lamps - SAE J595 (11/2008) Directional Optical Warning Devices for Authorized Emergency, Maintenance, and Service Vehicles A directional warning lamp is a flashing optical warning device, in which the light source produces flashes of light, which are directionally aimed, and will project a signal over a minimum area from 20 right to 20 left in a horizontal plane and from 10 up to 10 down in a vertical plane. The flashes of light may be a repetitive signal or a non-repetitive signal. If a non-repetitive signal is used, it shall be a block of repetitive signals that have been characterized. 2. Omni-Directional (360 ) Lamps - SAE J845 (12/2007) Optical Warning Devices for Authorized Emergency, Maintenance, and Service Vehicles An omni-directional warning lamp is a flashing optical warning device that projects light in a horizontal 360 degree arc and vertically from 5 degrees up to 5 degrees down. It will appear to project flashes of light to an observer positioned at a fixed location. The flashes of light may be a repetitive signal or a non-repetitive signal. If a non-repetitive signal is used it shall be a block of repetitive signals that have been characterized. This would include all 360 beacons. 3. Selective Coverage Lamps - SAE J845 (12/2007) Optical Warning Devices for Authorized Emergency, Maintenance, and Service Vehicles A selective coverage warning lamp is a flashing optical warning device that projects light in a defined horizontal arc of more than 40 degrees, but less than 360 degrees and vertically from 5 degrees up to 5 degrees down. It will appear to project flashes of light to an observer positioned at a fixed location within the arc of coverage. The flashes of light may be a repetitive signal or a non-repetitive signal. If a non-repetitive signal is used it shall be a block of repetitive signals that have been characterized. This would include all directional and oscillating warning devices, and omni-directional devices within a light bar that have the light beam blocked by internal components. There are three classes for all three types of Warning/Hazard lamps. Class 1 Class 1 Optical Warning Devices are primary optical warning devices for use on authorized emergency vehicles responding to emergency situations. These devices are utilized to capture the attention of motorists and pedestrians and warn of a potentially hazardous activity or situation. Class 2 Class 2 Optical Warning Devices are primary optical warning devices for use on authorized maintenance or service vehicles to warn of traffic hazards such as a lane blockage or slow moving vehicle. Class 3 Class 3 Optical Warning Devices are primary optical warning devices for use on vehicles authorized to display an optical warning device for identification only. 360 >40 - <

5 Each type and class of warning lamp has 4 colors. White For our market this color is mainly used in school bus applications. It is also used in the emergency, or Red and Blue, market. Amber (or Yellow) Used to warn and alert in industries such as agriculture, construction, and waste management. This color is the primary color of the market we at Grote service. Red Red is mainly used in the emergency market, but can be used in other markets depending on state law. Key Points Grote services the Amber or yellow types of warning lamps. Blue Mainly used in the emergency market, but can be used in other markets depending on state law. TYPES OF WARNING/HAZARD LIGHTS LED Beacon These beacons are made with LED s that flash in a way that imitates a strobe flash. These lights are powered by an electronic circuit board. This board is usually potted in epoxy to protect the board and its solder connections from breaking from vibration. ( Potted means that the electronics sit in a pot when the electronic board is in place in production. Hot epoxy is then poured into the pot allowing it to fill all around the electronics. When it cools it hardens all around the electronic circuit board.) LED s can come with different flash patterns: Single, Double, Quad (4), or Quint (5). This refers to how many times the light flashes per interval and the number of flashes per minute (FPM). Key Points FPM = Flashes per minute. Strobe Beacon These beacons are made with a strobe tube that is filled with xenon gas that gives off a bright flash every time there is a high voltage electrical discharge. The power to this light is derived from an electrical circuit board in the base of the lamp which is usually potted in epoxy. Strobes can come with different flash patterns: Single, Double, or Quad. This refers to how many times the light flashes per interval. Rotating Beacon These beacons are made with an incandescent or halogen light source. They will have a reflector in them that rotates and gives off a pop or concentration of light. These lights have a motor in them that drives the rotating reflector. Directional Lights These lights face out and flash in one direction only. These systems are commonly seen on the back of trucks so that the traffic coming upon them from behind can identify a cautionary situation and move over. There are several forms of Directional Lights. Single This is one light source that flashes in a specified pattern. 5

6 2-Head System This system consists of two light sources that can flash in a synchronized flash pattern or an independent flash pattern. 4-Head System This system consists of four light sources that can flash in a synchronized flash pattern or an independent flash pattern. Mini light bars These are light bars that are under 36 inches in length. They can have Rotating lights, strobe lights, and LED light modules. These can have multiple flash pattern options which user can select a preferred pattern and wire lamp accordingly. These can be mounted permanently or can be removable. Light Bars Full size light bars are 36 inches to roughly 57 inches in length and mount permanently on the roof of a vehicle. They can have all the same lighting features as a mini light bar. Directional Arrows These lights are designed to warn oncoming traffic to move over in a certain direction. The lights will light up sequentially in the direction the traffic is supposed to go. Hide-A-Way Systems These are light systems that are hidden in the headlights or taillights. When they turn on, they will light up the headlight and tail light assemblies and flash in a controlled pattern. These may use strobe tubes or LED s with a separate power supply. Each light source uses a different power source. OTHER TYPES OF WARNING/HAZARD DEVICES Back Up Alarms These are alarms that are engaged when a vehicle is put in reverse and give an audible signal to warn people when a vehicle is backing up. Some back up alarms are potted, but some are not. Back up alarms are governed by OSHA 1926, which sets the warning requirements for all vehicles with an obstructed view to the rear. OSHA 1926 states: Motor Vehicles and Mechanized Equipment No employer may use any motor vehicle, earthmoving, or compacting equipment having an obstructed view to the rear, unless: The vehicle has a reverse signal alarm distinguishable from the surrounding noise level, or The vehicle is backed up only when an observer signals that it is safe to do so. 6

7 POPULAR GROTE PRODUCTS BY TYPE OF LIGHT LED Strobe Beacons Class II This beacon is an economical beacon for an LED light. It should be used in low vibration applications as the electronics are not potted. The LED is not replaceable. Three mounting holes with mounting hardware on black anodized aluminum base for resistance against corrosion Gasketed amber polycarbonate high impact lens is fastened onto the base to enclose and protect the LED circuit board assembly 12 Volt Quad flash pattern is ideal for material handling equipment 63 FSPM (flash sequences per minute) in Quad flash mode LEDs feature long-lasting low amp draw for maintenance-free operation 8 rows (77863) of high-intensity surface mounted LEDs wrapped around a 6063 aluminum heat-sink to dissipate heat Class I This strobe can be used for high vibration situations and is a very durable LED strobe. The LED lights are not replaceable. Eight 3 watt LEDs provide unrivaled flash intensity Double (80) or Quad (65) flash operation with hi/lo intensity control Die cast aluminum base is coated against corrosion and designed for vibration resistance and heat dispersion Thread-on polycarbonate lens allows for easy no-tool pattern selection Reverse polarity, voltage spike and surge protected 12 to 24 VDC operation spread 7

8 Strobe Beacons Class II This is an economical strobe that uses a replaceable flash tube. The electronics are waterproof because they are potted in epoxy. Three wire leads allow user to choose double flash or quad flash Field replaceable flash tube (no tools required) Heavy duty epoxy filled, reinforced nylon base UV stabilized polycarbonate thread-on lens allows user to change the flash tube without tools Voltage spike and surge protected 80 (Double) or 65 (Quad) flashes per minute CLASS I: Clear, Red, Yellow, Blue CLASS I, SMART STROBE : Red, Yellow, Blue CLASS II, HEAVY DUTY: Yellow, Clear, Red, Yellow, Blue CLASS II, EPOXY BASE: Red, Blue This is a high end light that uses a strobe tube. The potted version is for use in high vibration scenarios and is weather-proof. This model comes in several versions that meet different levels of light output required for each Class. Popular with school buses and construction equipment 2 mounting options: external and 1 pipe Field selectable double or quad flash and intensity Epoxy version has a potted circuit board for added protection against vehicle vibration and road shock Smart Strobe flash intensity automatically adjusts for day and night working conditions Thread-on lens Joules: Class I 15/20; Class I, Smart Strobe 10/20; Class II 8/17 Flashes per minute: Class I 65/80; Class II 60/65 Field selectable Double or Quad flash Class I have an LED indicator that lights up to alert flash tube failure (not applicable on Class II Heavy Duty lamps) 8

9 77013 This lamp is for off-road use and is a Class III lamp used primarily for the fork lift market. Electronics sealed in epoxy to protect against dust, moisture, and vibration Thread-on lens for easy maintenance Field replaceable flash tube Meets UL-583 and SAE J1381 vibration requirements 80 flashes per minute (single flash) 2 joules per flash This lamp is another version of the lamp used for the fork lift market. It is a Class III lamp that is available in a permanent or magnetic mount. Thread-on lens for easy maintenance Polycarbonate lens and fiber glass filled Nylon base Reverse polarity and voltage spike protected 45 lbs. pull magnet for temporary mounting, with 12 adapter plug 1.5 joules per flash, 70 flashes per minute (single flash) Replaceable flash tube Removable 1/2 hood included Directional LED Strobes Class II This directional strobe light is mounted on the rear of a vehicle to warn other vehicles approaching from behind that there is a slow or stopped vehicle on the road ahead of them. It is primarily used on garbage trucks and trucks working on the road. Encapsulant potting protects the circuit board offering maximum protection against dirt, moisture, and corrosion Internal circuitry eliminates the need for an external power supply or control module Requires only a 12-volt DC connection for power Functions as either a dual flash strobe or a quad flash strobe Lamps fit 4 inch standard mounting Lamps mount in any orientation Grote s rugged Plug-and-Go terminals make for a quick, easy connection every time 9

10 Class II This directional light is mounted on the rear of a vehicle to warn other vehicles approaching from behind that there is a slow or stopped vehicle on the road ahead of them. This strobe is primarily used on garbage trucks and trucks working on the road. Encapsulant potting protects the circuit board offering maximum protection against dirt, moisture and corrosion Internal circuitry eliminates the need for an external power supply or control module Requires only a 12-volt DC connection for power Functions as either a dual flash strobe or a quad flash strobe Lamps fit oval standard mounting holes Lamps mount in any orientation Grote s rugged Plug-and-Go terminals make for a quick, easy connection every time Class I This directional light is mounted on the rear of a vehicle to warn other vehicles approaching from behind that there is a slow or stopped vehicle on the road ahead of them. It is primarily used on road construction trucks working on the road. This is a sealed and potted unit. Utilizes four high-intensity 1 watt Luxeon LEDs and ribbed optics for maximum light dispersion User selectable Steady Burn, Double, Quad, or Quint flash modes 74 FSPM in Double, Quad, and Quint modes Class II This directional light is mounted on the rear of a vehicle to warn other vehicles approaching from behind that there is a slow or stopped vehicle on the road ahead of them. It is primarily used on road construction trucks working on the road. It is sealed by a rubber gasket, but is not potted. The LEDs are not replaceable. 42 individual 1/4 watt LEDs with individual reflectors Tough, clear polycarbonate housing with urethane encapsulated electronics flashes per minute 10

11 Directional Strobe Systems Class I This directional light is mounted on the rear of a vehicle to warn other vehicles approaching from behind that there is a slow or stopped vehicle on the road ahead of them. It is primarily used on road construction trucks working on the road. It is sealed by a rubber gasket, but is not potted The strobe tubes are replaceable. Double or Quad flash options enhance rear vehicle warning 60 flash per minute Package includes:(1) power supply, (2) oval strobe,(2) cable, and (1) rocker switch, (2) oval grommets Class II Twist-in socket design for flash tube replacement Vibration and shock resistant construction Polycarbonate lens and base Yellow, 6 Lamp System - Class II (strobe function only) Yellow, 4 Lamp System - Class II (strobe function only) Lamp flashes function in an alternating X pattern Lower amp pull with use of LED lamps System can be wired so the lamps operate as turn signal lamps when the turn signal is activated; then return to strobe function when turn signal is cancelle System uses sealed UBS wiring and SuperNova LED lamps to maximize protection from moisture and corrosion Kit contains necessary grommets, pigtails and installation instructions Ideal for refuse vehicles and highway maintenance equipment Four-lamp system has two oval and two round lamps; six-lamp system has two oval and four round lamps 11

12 Rotating Beacons Rotating beacons are very economical lights for low vibration applications. They provide a 360 degree warning and meet Class I specifications Class I Clutched gear box is sealed and permanently lubricated Revolves 360º, flashes per minute Class I Self-lubricating heavy-duty motor and gear assembly Thread-on lens for easy maintenance Durable, three-point rotating assembly dissipates shock Non-corrosive base 50 watt, halogen bulb, 100 flashes per minute Permanent mount hardware included Yellow Green Blue Low power consumption light Cigarette lighter plug with coiled cord Magnetic mount 12

13 Mini Light Bars Yellow, Permanent Mount - Class II Yellow, Magnet Mount - Class II Low profile mini-light bar provides high performance characteristics of LED lighting in a small size. 6 internal LED modules provides 360 light output Built-in electronic flasher with 30 Scan-Lock flash patterns plus 4 simulated rotating patterns (permanent mount version only) Permanent mount includes 6 pigtail; magnetic mount includes 8 straight cord with accessory plug that includes LED indicator switch Permanent mount to be mounted on 14 1/16 x 3 7/16 hole centers Class I Permanent mount hardware included Dual belt drive rotators 55 watt, halogen bulbs 480 flashes per minute Sleek, low-profile lens design Silicon belt and stainless steel bearings for long life; belt is resistant to heat and UV light damage Light Bars Class I 55 watt flood lamps Rear brake/tail function Mounts to tow truck pylon 50 watt, halogen warning lamps Simple dome removal 13

14 Directional Arrows Class I Extruded aluminum housing and clear polycarbonate LED module (illuminates amber) Epoxy sealed electronics provide maximum environmental protection Wig-Wag and alternating flash patterns 35 cable length Signal and Control Head w/ 35 Harness Signal and Control Head w/ 15 Harness Compact control head provides in-cab feedback of arrow pattern on an LED display Rugged extruded aluminum housing Flash right, flash left, center out, and Wig-Wag patterns Will mount on most bar lights Hide-A-Way Systems The next three products below are the components that make up a Hide-A-Way system using strobe tubes. They use a power supply in the cab of the vehicle. The strobe tubes are mounted in the head lights and tail lights and are connected to the power supply via cables to the strobe tubes Head Four outlet power supply Hi/low power control User selectable double or quad flash For use with 7726 models Each strobe outlet flashes 60 cycles per minute Alternating pairs outlet flashes 120 cycles per minute volts 14

15 Cable Double jacketed cable Packard connection For use with Grote remote strobe systems Grote offers several options for replacement flash tubes. See part listing for recommended tube replacement part number Yellow Red Blue This is the latest technology in Hide-A-Way lighting. This light system consists of an ultra-small, self-contained, hemispheric LED light, for surface mount or internal mount, within composite headlights, cornering lights, and taillight assemblies. This type of application is where the industry is trending for all new equipment. Ultra small, self-contained, hemispheric LED light, for surface mount or internal mount within composite headlight, cornering lights and taillight assemblies. Flange kit options in black or chrome allow easy surface mounting anywhere on your vehicle. 25 Scan-Lock flash patterns, includes synchronize feature for alternating and synchronous flashing of multiple lamps. Simple installation with no separate lamp drivers, flashers, ballast or power supplies to install. 15

16 Back-up Alarms This is the most popular back up alarm because it meets the minimum decibel requirement of the SAE Standards and complies with OSHA regulations. Electronics sealed in epoxy for protection against dust, vibration, and moisture Self-grounding, eliminates potential corrosion points Universal integral mounting bracket Voltage spike and surge protected UL Approved Decibels, Smart Alarm This is a heavy duty alarm that adjusts the level of the alarm based on surrounding noise. This unit has the speaker mounted backwards so the unit is able to withstand high pressure washing equipment. Electronics sealed in epoxy for protection against dust, vibration, and moisture Measures ambient noise level and instantly self-adjusts to at least 5 decibels louder Automatically adjusts to eliminate user s confusion on which volume to select Volume decibels Universal mount NOTES ADDITIONAL RESOURCES These resources can be acquired online or through the marketing department. 16