Whelen 60A02SAR User Manual

®

ENGINEERING COMPANY INC.

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

Installation Guide:

600 Series

Super-LED® Lighthead

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

©2004 Whelen Engineering Company Inc.
Form No.13900J (051911)

Page 1

Installation:

IMPORTANT! It is the responsibility of the installation technician to make sure
that the installation and operation of this product will not interfere with or
compromise the operation or efficiency of any vehicle equipment!

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.

5.750"

2.875"

Hi/Low Intensity (Violet) - This feature allows the user to step the unit down to low
power operation for nighttime use. Apply positive voltage to the VIOLET wire to put
the lighthead into low power. Remove the voltage from the VIOLET wire to restore
normal high power operation.

The table below provides wiring information for the 600 Series lighthead. Refer to the
appropriate Flash Pattern list as determined by the lighthead style:

WARNING! The LED models designated “Steady” must be connected to an
electronic flasher. Allowing the LED to steady burn will damage the lighthead
and void the warranty.

This product draws significantly less current than a

standard incandescent automotive bulb. If your flasher does not operate
properly, it may be necessary to replace your existing flasher module with a
Whelen 3TERM flasher module. Contact your sales representative for specific
vehicle application.

1.625"

1" diameter hole

1/4" diameter
hole (4 places)

3.250"

1. Using the dimensions shown, mark off and drill the four 1/4” diameter mounting
holes and the 1” wire hole into the mounting surface. Check measurements
before drilling.

2. Install the screw grommet flange into the mounting holes then install a rubber
grommet (customer supplied) into the wire hole.

3. Using appropriately sized wires (minimum 18 AWG wire), extend the lighthead
wires to their appropriate connections. Fuse the positive connections at 3
Amps and test operation of lighthead before securing it to vehicle.

4. Position the lighthead onto the mounting surface and secure to the vehicle

using the four #6 x 1-1/2” sheet metal screws.

Wiring:

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
BREAKERS WITH THIS PRODUCT!

The 600 Series lighthead offers the user various features depending on the model.
These features and their usage are as follows:

Scan-Lock™ (White/Violet):

Note that the lighthead must be on to use the ScanLock feature except where
noted.

To advance to the next flash pattern - Apply +12VDC to the WHT/VIO wire for less
than 1 second and release.

To cycle backwards through the flash patterns - Apply +12VDC to the WHT/VIO
wire for more than 1 second and release.

To reset to the factory default flash pattern - Turn off power to the lighthead. While
applying +12VDC to the WHT/VIO wire, turn power to the lighthead on. Continue to
apply voltage to the WHT/VIO wire for 5 seconds. The default pattern will now be
active.

NOTE: A Normally Open momentary switch is suggested to activate the Scan­Lock™ wire.

SYNC (Grey) - 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. When the lightheads are activated, their patterns will be synchronized. To
configure the two lightheads to alternate their patterns, advance the pattern of either
lighthead to the Phase 2 mode of the current pattern. Remember, Phase 1 patterns

ALWAYS

alternate with Phase 2 patterns!

at the battery to carry that load. DO NOT USE CIRCUIT

600 Series Lighthead Wiring

Style Wiring Pattern Table

Steady (12V) - LED Color (Power) . . . . . . . N/A (see “WARNING” above)

Steady (24V) - LED Color (Power) . . . . . . . N/A (see “WARNING” above)

SYNC - LED Color (Power) . . . . . . . SYNC Pattern Table

Split - LED-1 Color (Power) . . . . . Split Pattern Table

Hi/Low (12V) - LED Color (Power) . . . . . . . Standard Pattern Table)

Hi/Low (24V) - LED Color (Power) . . . . . . . Standard Pattern Table)

SYNC Pattern Table:

Sync-Capable Flash 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

7. SingleFlash 75 - Phase 1

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

Split Pattern Table:

1. SignalAlert 75 - Alt.

2. SignalAlert 75 - Sim.

3. CometFlash - Alt.

4. CometFlash - Sim.

5. DoubleFlash150 - Alt.

6. DoubleFlash150 - Sim.

7. DoubleFlash75 - Alt.

Standard Pattern Table:

1. SignalAlert™75

2. SignalAlert150

3. SingleFlash 375

4. SingleFlash 150

5. SingleFlash 75

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

- BLK (Ground)

- BLK/WHT (Ground)

- BLK (Ground)

- GRY (SYNC)

- WHT/VIO (Scan-Lock™)

- LED-2 Color (Power)

- BLK (Ground)

- WHT/VIO (Scan-Lock)

- BLK (Ground)

- VIO (Hi/Low Power)

- WHT/VIO (Scan-Lock)

- BLK/WHT (Ground)

- VIO (Hi/Low Power)

- WHT/VIO (Scan-Lock)

Non-Sync Flash Patterns:

15. SingleFlash 60*

16. SingleFlash 90*

17. SingleFlash 120*

18. SingleFlash 300

19. DoubleFlash 150

20. ComAlert 150

21. ActionFlash™ 50

22. ActionFlash 150

23. ModuFlash™

24. ActionScan™

25. Steady

* = California Title XIII compliant

8. DoubleFlash75 - Sim.

9. SingleFlash375 - Alt.

10. SingleFlash375 - Sim.

11. SingleFlash150 - Alt.

12. SingleFlash150 - Sim.

13. SingleFlash75 - Alt.

14. SingleFlash75 - Sim.

6. DoubleFlash 150

7. DoubleFlash 75

8. CometFlash®75

9. ActionFlash

10. ModuFlash

15. ActionFlash - Alt.

16. ActionFlash - Sim.

17. ModuFlash - Alt

18. ModuFlash - Sim.

19. ActionScan - Alt.

20. SSNF

11. ComAlert

12. ActionScan

13. SignalAlert

14. Steady

Page 2

CAUTION! DO NOT LOOK DIRECTLY AT THESE LED’S WHILE THEY ARE ON.

IMPORTANT WARNING!

MOMENTARY BLINDNESS AND/OR EYE DAMAGE COULD RESULT!