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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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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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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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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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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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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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)
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