Whelen 200 User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]

TIR6™ Super-LED® Lighthead

Installation Guide:

200 Series / 4” Round

Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

Safety First

This document provides all the necessary information to allow your Whelen product to be properly and safely installed.
Before beginning the installation and/or operation of your new product, the installation technician and operator must
read this manual completely. Important information is contained herein that could prevent serious injury or damage.

• Proper installation of this product requires the installer to have a good understanding of automotive electronics,
systems and procedures.

• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other
vital parts could be damaged by the drilling process. Check both sides of the mounting surface before drilling
begins. Also de-burr any holes and remove any metal shards or remnants. Install grommets into all wire
passage holes.

• If this manual states that this product may be mounted with suction cups, magnets, tape or Velcro®, clean the
mounting surface with a 50/50 mix of isopropyl alcohol and water and dry thoroughly.

• Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted or
located in the air bag deployment area will damage or reduce the effectiveness of the air bag, or become a
projectile that could cause serious personal injury or death. Refer to your vehicle owner’s manual for the air bag
deployment area. The User/Installer assumes full responsibility to determine proper mounting location, based
on providing ultimate safety to all passengers inside the vehicle.

• For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be
made. The recommended procedure requires the product ground wire to be connected directly to the NEGATIVE
(-) battery post.

• If this product uses a remote device to activate or control this product, make sure that this control is located in
an area that allows both the vehicle and the control to be operated safely in any driving condition.

• Do not attempt to activate or control this device in a hazardous driving situation.

• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a combination of these
lights. Do not stare directly into these lights. Momentary blindness and/or eye damage could result.

• Use only soap and water to clean the outer lens. Use of other chemicals could result in premature lens cracking
(crazing) and discoloration. Lenses in this condition have significantly reduced effectiveness and should be
replaced immediately. Inspect and operate this product regularly to confirm its proper operation and mounting
condition. Do not use a pressure washer to clean this product.

• It is recommended that these instructions be stored in a safe place and referred to when performing
maintenance and/or reinstallation of this product.

• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO
THE PRODUCT OR VEHICLE AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Automotive: Lightheads

For warranty information regarding this product, visit www.whelen.com/warranty

©2003 Whelen Engineering Company Inc.
Form No.13778E (062007)

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Mounting: Trim Ring (optional)

Mounting: Grommet (optional)

Caution: Permanent
mounting of this product
will require drilling. It is
absolutely necessary to
make sure that no other
vehicle components could
be damaged by this
process. Check both sides
of the mounting surface
before starting. If damage is
likely, select a different
mounting location.

WARNING! All customer supplied wires that connect to the positive
terminal of the battery must be sized to supply at least 125% of the
maximum operating current and FUSED
DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

1. Position the flange onto the
proposed mounting location. Using
a scribe or similar tool, mark off the
mounting holes. Also mark the area
in the center where the 1” wire
passage hole will be drilled.

IMPORTANT: Always be sure to check all
measurements before drilling.

2. Using a drill bit sized for a #8 sheet
metal screw and the thickness of the
mounting surface, drill the 3 mounting holes.

3. Drill a 1” dia. wire passage hole in the area marked. Be sure to deburr and
install a grommet (customer supplied) into this hole.

4. Using appropriately sized wires (minimum 18 AWG), extend the lighthead
wires to their designations. Fuse the +12VDC connections at 3 Amps and
test for proper operation.

5. Secure the lighthead to the vehicle using the supplied mounting
hardware.

120°

MOUNTING CONFIGURATION

at the battery to carry that load.

4.80” BOLT CIRCLE

MOUNTING HOLE FOR
#8 SHEET METAL SCREW
(3) PLACES TYP.

1.00” DIA
WIRE ACCESS HOLE

Wiring:

Wire Color Function Connect to:

LED Color. . . . . . . . . . . . . . . . . . . . Power Switched +12VDC

Black . . . . . . . . . . . . . . . . . . . . . . . Ground . . . . . . . . . . . . . . Chassis Ground

Grey . . . . . . . . . . . . . . . . . . . . . . . . Sync . . . . . . . . . . . . . . . . . . . . . . . See text

White/Violet . . . . . . . . . . . . . . . . . . Scan-Lock™ . . . . . . . . . . . . . . . . . See text

GROMMET MOUNTING / HOLE CHART

Mounting Surface

Thickness

.0625” (1/16”)

.125” (1/8”)

.1875” (3/16”)

.25” (1/4”)

.375” (3/8”)

Mounting Hole

Diameter

4.47”

4.50”

4.50”

4.53”

4.56”

IMPORTANT! Make sure the lighthead will not interfere with existing equipment
and be aware of any items on the opposite side of the mounting surface.

1. Mark the center of the mounting location onto the mounting surface.
Scribe a circle onto the mounting surface using this point as the center.
Refer to the mounting hole chart for the proper diameter.

2. Cut and deburr the grommet hole.

3. Using appropriately sized wires (Minimum 18 AWG), extend the lighthead
wires to their designations. Fuse the +12VDC connections at 3 Amps and
test for proper operation.

4. Insert the lighthead into the grommet then secure it to the vehicle by
snapping the grommet into the mounting hole.

IMPORTANT WARNING!

CAUTION! DO NOT LOOK DIRECTLY AT THESE LED’S WHILE THEY ARE ON.
MOMENTARY BLINDNESS AND/OR EYE DAMAGE COULD RESULT!

Operation - This lighthead features Scan-Lock™ selectable flash patterns and
SYNChronization capabilities.

Scan-Lock™ - To cycle forward through patterns, with the lighthead
switched on, apply +12VDC to the WHT/VIO wire for less than 1 second and
release. To cycle backward through patterns, apply +12VDC to the WHT/
VIO wire for more than 1 second. When the desired pattern is displayed, allow
it to run for more than 5 seconds. The lighthead will now display this pattern
when active. To reset to the factory default pattern, turn off power and apply
+12VDC to the WHT/VIO wire while turning power back on.

SYNC lightheads have a special set of flash patterns, with each pattern
available in two modes; Phase 1 and Phase 2. All lightheads configured to
display the Phase 1 mode of a given pattern will flash simultaneously. Any
lightheads configured to display the Phase 2 mode of a pattern, will alternate
with any Phase 1 lightheads with the same pattern.

Sync - To sync two lightheads, configure both lightheads to display the same
Phase 1 pattern. With the power off, connect the GREY wires from each
lighthead together. When the lightheads are activated, their patterns will be
synchronized. To configure the two lightheads to alternate their patterns, set
the pattern of either lighthead to the Phase 2 mode of the current pattern.

To understand how to use the SYNC feature with more than 2 lightheads, the
principals will be applied to a sample system consisting of 4 lightheads with 2
mounted on the rear, driver side of the vehicle and 2 mounted on the rear,
passenger side of the vehicle.

With all the wiring complete, turn on the 4 lightheads. As shipped from the
factory, all the lightheads will simultaneously display the same pattern
(SignalAlert™ 75 Phase 1).

To configure, for example, the passenger side lightheads to alternate with the
driver side lightheads, change the flash patterns for either the passenger or
driver side lightheads to Phase 2 mode of the same pattern.

Available 4-wire Flash Patterns /

SYNC Patterns:

1. SignalAlert™ 75 Phase 1

2. SignalAlert™ 75 Phase 2

3. CometFlash® 75 Phase 1

4. CometFlash® 75 Phase 2

5. DoubleFlash 75 Phase 1

6. DoubleFlash 75 Phase 2

= California Title XIII compliant

*

8. SingleFlash 75 Phase 2*

9. ComAlert™ 75 Phase 1

10. ComAlert™ 75 Phase 2

11. LongBurst™ 75 Phase 1

12. LongBurst™ 75 Phase 2

13. PingPong™ 75 Phase 1

14. PingPong 75 Phase 2

7. SingleFlash 75 Phase 1

Standard Patterns:

1. SingleFlash 60*

2. SingleFlash 90*

3. SingleFlash 120*

4. SingleFlash 300

5. DoubleFlash 150

IMPORTANT! Before returning the vehicle to active service, visually confirm the proper operation of this product, as well as all vehicle components/equipment.

6. ComAlert™150

7. ActionFlash™1

8. ActionFlash 2

9. ModuFlash™

10. ActionScan™

11. Steady

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