Carson Marine Safety Devices HPK 100 User Manual

Carson Manufacturing Co., Inc.  
5451 North Rural Street  
Indianapolis, IN 46220  
Phone: (888) 577-6877 Fax: (317) 254-2667  
HPK-100  
HORN SYSTEM  
HORN SELECT  
LITE  
V
E
H
A
I
R
O
O
F
N
F
CSP-100B  
100W 11 OHM  
INSTALLATION AND OPERATING  
INSTRUCTIONS  
This product is legal in most states.  
Please consult your state/local vehicle codes to ensure compliance with vehicle horn regulations.  
Carson is a trademark of Carson Manufacturing Company, Inc.  
 
HPK-100 Installation and Operating Instructions  
Page 3 of 8  
INSTALLATION  
Proper installation of the system is essential for years of safe, reliable operation. Please read all  
instruction before installing the system components. Failure to follow these instructions can  
cause serious damage to the components 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.  
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.  
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 horn system 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.  
UNPACKING  
Inspect contents for shipping damage. If found alert carrier immediately.  
Contact supplier immediately if any components are missing.  
Contents of box should include the following items:  
Qty Item  
1
1
1
1
6
6
1
Amplifier Unit (HA-100-10 14)  
Speaker, 100W 11 ohm (CSP-100B)  
Switch Panel (SP-200)  
Connector, 4-P Terminal Block Plug (CP4688-04)  
Screw, Hex #8 Self Drilling (CP4051-XK-12)  
Terminal, 3/16” Insulated Fem. Q.C. (CP4062-K2545)  
Instruction Manual (CP5060 This Manual)  
CP5060A  
02/04/10  
 
Page 4 of 8  
HPK-100 Installation and Operating Instructions  
MOUNTING  
Amplifier  
Select a location for the amplifier in an area such as the driver compartment firewall, under a seat,  
etc. Mounting the amplifier in the engine compartment or in an area directly exposed to weather  
is not recommended. Allow clearance for wiring. Inspect behind mounting area for clearance.  
Install the terminal block plug and make all electrical connections before final mounting. Use #8  
screws (supplied loose) for mounting.  
Speaker  
The speaker is weather resistant and is intended to be mounted on the outside of the vehicle or  
under front hood. Mount the speaker facing forward and as far forward on the vehicle as possible  
to minimize sound exposure to occupants. Choose a location that minimizes obstructions in front  
of the speaker to maximize forward sound. Attach the speaker to a sturdy part of the vehicle to  
prevent vibration and possible damage. Attach the speaker angled slightly toward the road so the  
front openings will drain off any fluids. Cover openings of speaker while drilling any holes.  
DO NOT get metal shavings inside the speaker.  
Switch Panel  
Mount the switch panel underneath the vehicle dash board using #8 screws (supplied loose).  
Locate the panel away from the driver’s or passenger’s legs. Allow clearance for wiring. Inspect  
behind mounting area for clearance. Make all electrical connections before final mounting.  
ELECTRICAL CONNECTIONS  
Amplifier  
Electrical connections to the amplifier are made using a removable terminal block plug (supplied  
loose) located on the side. A label on the amplifier identifies each terminal function. You should  
install the plug on the amplifier before wiring. If the unit needs service the plug can be easily  
removed without unwiring. The amplifier is fused near the connector. 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. Most vehicle horn circuits with relays provide adequate power  
on the vehicle horn side of the relay. However do not provide power to both the vehicle horn and  
this amplifier from one horn relay circuit as this will exceed circuit rating.  
NOTE: Permanent disconnection of the vehicle horn is NOT recommended.  
Attach leads by stripping 3/8", inserting into plug 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.  
Switch Panel  
Electrical connections to the switch panel are made using 3/16” quick-connect terminals (supplied  
loose).  
Wire Size and Termination - The diagram shows the minimum wire size used for each connec-  
tion, 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.  
02/04/10  
CP5060A  
 
HPK-100 Installation and Operating Instructions  
Page 5 of 8  
ELECTRICAL CONNECTIONS CONTINUED  
NOTE: Permanent disconnection of the vehicle horn is NOT recommended.  
BLK #22G -VDC FOR LAMP  
ADD PROPER FUSE  
12V  
LAMP  
LITE  
SWITCH  
20A MAX.  
Recommended  
Wire Size  
RED +VDC IN  
RATED 15A @ 12VDC  
YEL +VDC OUT  
Amps  
5 - 10  
Size  
#16G  
#14G  
Lite  
10 - 15  
Use next larger  
size  
if longer than 10 ft.  
OBSERVE  
SWITCH TERMINAL  
SPACING FOR  
ORIENTATION  
SEE  
WIRE SIZE TABLE  
UNDER HOOD  
ORG or RED #16G  
HORN SELECT  
SWITCH  
+VDC  
HORN  
RELAY  
CIRCUIT  
RATED 15A @ 12VDC  
HORN  
RELAY  
Splice  
OBSERVE  
SWITCH TERMINAL  
SPACING FOR  
ORIENTATION  
GRN #16G  
BLU #16G  
Break  
Connection  
Splice  
Vehicle  
Horn  
If the “HORN RELAY CIRCUIT” provides -VDC:  
Connect “ORG or RED #16G” wire to +VDC supply  
and connect “#16G BLK” to “HORN SELECT SWITCH”.  
ORG or RED #16G  
CSP-100B  
SPEAKER  
100W 11 ohm  
#16G BLK to -VDC  
Splice  
Splice  
#18G BRN  
#18G BRN  
#18G BRN  
#18G WHT  
4-P Terminal Block Plug  
(CP4688-04)  
Plug installed  
this orientation  
USE  
WATERPROOF  
BUTT CONNECTORS  
FOR UNDER HOOD SPLICES  
Plug into unit first for  
terminal identification  
15A Automotive  
Type Fuse  
CP5060A  
02/04/10  
 
Page 6 of 8  
HPK-100 Installation and Operating Instructions  
ELECTRICAL CONNECTIONS CONTINUED (NOT USING SWITCH PANEL)  
NOTE: Permanent disconnection of the vehicle horn is NOT recommended.  
Horn  
Circuit  
HORN RLY  
Vehicle  
Horn  
Momentary  
SPST  
+VDC  
Amplifier Power  
Connection Examples  
Switch  
Splice  
+VDC  
Added  
SPDT  
Switch  
+VDC  
Assumes Power is +VDC  
Added  
Relay  
May be powered with  
-VDC instead, just change  
to -VDC and Amp NEG in  
diagrams.  
Note:  
Vehicle  
Horn  
To  
Amp POS  
Vehicle horn  
will also sound  
To Amp POS  
To Amp POS  
#16G RED to +VDC  
#18G BRN  
#16G BLK to -VDC  
#18G BRN  
4-P Terminal Block Plug  
(CP4688-04)  
Plug installed  
this orientation  
15A Automotive  
Type Fuse  
Plug into unit first for  
terminal identification  
OPERATION  
USING SWITCH PANEL  
In an emergency situation, set the HORN SELECT switch to AIR and turn on the LITE switch in  
one sweeping motion. When the horn ring on the vehicle is pressed the amplifier and speaker  
produce a simulated air horn sound. An output indicator on the side of the amplifier also lights up.  
The output indicator is located opposite the end with connector.  
When the emergency is over, turn off the LITE switch and set the HORN SELECT switch to VEH  
in one sweeping motion. When the horn ring is pressed the regular vehicle horn will sound.  
NOT USING SWITCH PANEL  
As soon as power is applied, the amplifier and speaker produce a simulated air horn sound and  
the output indicator lights up. The output indicator is located opposite the end with connector.  
02/04/10  
CP5060A  
 
HPK-100 Installation and Operating Instructions  
Page 7 of 8  
SERVICE  
The complete system consists of the amplifier, speaker, and switch panel components along with  
the wiring and electrical connections. A blown fuse on the amplifier does not necessarily  
mean the amplifier is bad. If the system stops functioning or exhibits problems, first check that  
the wire and electrical connections to each component are OK then check the following.  
On the switch panel, check for power into (center terminal) and out of the switch. On the HORN  
SELECT switch, check for power while pressing the horn ring. If there is not power into the  
switch, check wire for bad connections and check fuses or breakers in the circuit. If there is  
power into but not out of the switch, the switch itself may be bad.  
While activating the amplifier (with horn ring), look for the output indicator to light up. If it  
lights up the amplifier is OK. If not, check the fuse on the amplifier. If the fuse is OK then check  
the POS and NEG power input leads for good supply and ground connections. If power into the  
amplifier is OK then check that the voltage level at POS and NEG on the amplifier is less than the  
rated voltage. If the voltage level is OK then the amplifier may be bad.  
If the fuse on the amplifier is blown, disconnect the speaker leads at the amplifier and replace  
the fuse. As before, activate the amplifier and look for the output indicator to light up. If the fuse  
blows again then the amplifier may be bad.  
If the output indicator on the amplifier lights up, disconnect the leads at the speaker and  
check the speaker inputs with an ohm meter. If the reading is less than 1 ohm or reads as open  
circuit then the speaker may be bad. If the ohm meter reading is OK then the wiring or connec-  
tions between the amplifier and speaker may be faulty.  
The following chart shows typical symptoms and possible causes.  
PROBLEMS  
Symptom  
Possible Cause  
Power not applied  
Connector loose  
Fuse blown  
Check  
No power or  
output  
Is the output indicator light coming on?  
Is an external fuse or circuit breaker used?  
Are the negative leads connected to a good ground?  
Loose connection at power source  
High Voltage Protection  
Bad speaker  
Input voltage must be less than highest rated voltage.  
Try another speaker.  
Distorted sound Speaker assembly loose  
Low vehicle voltage  
Intermittent tone High Voltage Protection  
Connector loose  
Is the speaker bell or tip loose?  
Input voltage must be greater than lowest rated voltage.  
Is the vehicle voltage regulator working properly?  
Is the connector tight on the unit?  
Bad power connection  
Circuit breaker in supply connection  
PARTS and ACCESSORIES  
The following parts and accessories are available from Carson Manufacturing Company, Inc.:  
Part  
Description  
CP5030  
Cover, (not including chassis) (for amplifier)  
Fuse, 15 Amp Mini Automotive (for amplifier)  
Switch, Lighted Rocker (Lite switch on panel)  
Switch, Red Rocker ON - ON (Horn Select switch on panel)  
Transistor, output (2 required) (for amplifier)  
CP4990-150  
CP4993  
CP5044-2  
CP4998  
Accessory  
Description  
* - standard accessory supplied with unit  
ED1914  
Cable, 4-P Lead Assembly 15FT (made w/ CP4688-04 Conn) (for amplifier)  
Cable, 6-P Lead Assembly 15FT (made w/ 3/16” Q.C. Terminals) (for switch panel)  
Connector, 4-P Terminal Block Plug (for amplifier)  
ED1924  
CP4688-04  
*
CP4051-XK-12  
CP4062-K2545  
*
Screw, Hex #8 Self Drilling (for mounting)  
*
Terminal, 3/16” Insulated Fem. Q.C. (for switch panel)  
Manual, HPK-100 Instruction  
CP5060  
*
CP5060A  
02/04/10  
Page 8 of 8  
HPK-100 Installation and Operating Instructions  
or contact our Service Department at:  
E-mail [email protected] or Phone (888) 577-6877  
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  
If a product must be returned for any reason, please contact our Technical  
Service Department to obtain a Returned Merchandise Authorization num-  
ber (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.  
LIMITED WARRANTY  
Carson Manufacturing Company, Inc. warrants this new product to be free from defects  
in material and workmanship, under normal use and service, for a period of five (5)  
years from the date of delivery to the first user-purchaser.  
During this warranty period the obligation of Carson Manufacturing is limited to repairing  
or replacing, as Carson Manufacturing may elect, any part or parts of such product  
which after examination by Carson Manufacturing is determined to be defective in mate-  
rial and/or workmanship.  
This warranty does not cover labor charges for removal or re-installation of the product.  
Fuses and lamps and speakers are not covered under this warranty.  
This warranty does not extend to any unit that has been subjected to abuse, misuse,  
improper installation or which has not been adequately maintained, nor to units which  
have problems related to service or modification at any facility other than the manufac-  
turer.  
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING  
BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR  
FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL CARSON MANU-  
FACTURING COMPANY, INC. BE LIABLE FOR ANY LOSS OF PROFITS OR ANY  
INDIRECT OR CONSEQUENTIAL DAMAGES ARISING OUT OF ANY SUCH DEFECT  
IN MATERIALS OR WORKMANSHIP.  
02/04/10  
CP5060A  
 

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