Whelen 70A02SAR User Manual

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ENGINEERING COMPANY INC.

51 Winthrop Road Chester, Connecticut 06412-0684 Phone: (860) 526-9504

Installation Guide:

700 Series

Super-LED® Lighthead

Fax: (860) 526-4078 Internet: www.whelen.com Sales e-mail: autosale@whelen.com Canadian Sales e-mail: canadiansales@whelen.com Customer Service e-mail: custserv@whelen.com

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.

• Failure to use specified installation parts and/or hardware will void the product warranty!

• 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

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3.281"

2.375"

1.187"

6.562"

1" diameter hole

1/4" mounting hole

(4 places)

Installation:

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

IMPORTANT WARNING!

SCREW, 6 X 1-1/2" PPHSMS SS

GASKET

FLANGE GROMMET 700 SERIES

1/4" MOUNTING HOLE (4)

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.

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 flange grommet 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 supplied #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 700 Series lighthead offers the user various features depending on the model. Refer to the next page for wire designations and replacement parts.

Scan-Lock™ (White/Violet):

Note that the lighthead must be on to use the Scan-Lock™ 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

alternate with Phase 2 patterns!

ALWAYS

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 700 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. 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.

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

This product draws significantly less current than a

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

Split Pattern Table:

14. PingPong 75 - SIM*

15. SSNF 75

16. SingleFlash 60 - ALT

17. SingleFlash 60 - SIM

18. SingleFlash 90 - ALT*

19. SingleFlash 90 - SIM*

20. SingleFlash 120 - ALT*

21. SingleFlash 120 - SIM*

22. SingleFlash 300 - ALT

23. SingleFlash 300 - SIM

24. DoubleFlash 150 - ALT

25. DoubleFlash 150 - SIM

26. ComAlert™ 150 - ALT

4. SingleFlash 150

5. SingleFlash 75*

6. DoubleFlash 150

1. SignalAlert™ 75 - ALT

2. SignalAlert 75 - SIM

3. CometFlash 75 - ALT

4. CometFlash 75 - ALT

5. DoubleFlash 75 - ALT*

6. DoubleFlash 75 - SIM*

7. SingleFlash 75 - ALT*

8. SingleFlash 75 - ALT*

9. ComAlert™ 75 - ALT

10. ComAlert 75 - SIM

11. LongBurst™ 75 - ALT

12. LongBurst 75 - SIM

13. PingPong™ 75 - ALT*

Standard Pattern Table:

1. SignalAlert™75

2. SignalAlert150

3. SingleFlash 375

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

12. LongBurst 75 - Phase 2

13. PingPong™ 75 - Phase 1

14. PingPong 75 - Phase 2

Non-Sync Flash Patterns:

15. SingleFlash 60*

16. SingleFlash 90*

27. ComAlert 150 - SIM

28. ActionFlash™ - ALT 50

29. ActionFlash™ - SIM 50

30. ActionFlash™ - ALT 150

31. ActionFlash™ - SIM 150

32. ModuFlash™ - ALT

33. ModuFlash™ - SIM

34. DoubleFlash - ALT 120*

35. DoubleFlash - SIM 120*

36. PingPong™ - ALT 120*

37. PingPong™ - SIM 120*

38. TripleFlash™ - ALT 75*

39. TripleFlash™ - SIM 75*

7. DoubleFlash 75*

8. CometFlash®75

9. ActionFlash

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17. SingleFlash 120*

18. SingleFlash 300

19. DoubleFlash 150

20. ComAlert 150

21. ActionFlash™ 50

22. ActionFlash 150

40. TripleFlash™ 120 - ALT*

41. TripleFlash™ 120 - SIM*

42. SignalAlert CAL - ALT*

43. SignalAlert SIM - ALT*

44. ActionFlash™/SingleFlash

60/120 - ALT*

45. ActionFlash™/SingleFlash

60/120 - SIM*

46. ActionFlash™/SingleFlash

120/TF75 - ALT*

47. ActionFlash™/SingleFlash

120/TF75 - SIM*

48. CalScan™ - ALT + SIM*

10. ModuFlash

11. ComAlert

12. ActionScan

23. ModuFlash™

24. ActionScan™

25. Steady

* = California Title XIII compliant

49. ActionScan™ - ALT + SIM

50. SteadyFlash 60*

51. SteadyFlash 75*

52. SteadyFlash 90*

53. SteadyFlash 120*

54. Steady / Steady*

* = California Title XIII compliant

13. SignalAlert

14. Steady

* = California Title XIII compliant

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0 1 - 0 6 8 6 4 1 9 _ _ _

PART NUMBER KEY:

CONNECTOR

STYLE/VOLTAGE

LED/LENS COLOR

STYLE/VOLTAGE 1 = 2 = 3 = 4 = 5 = 6 = 7 =

STEADY/24V STEADY/12V LO-PWR/24V LO-PWR/12V SPLIT/12V SYNC/12V REMOTE SPLIT/12V

CONNECTOR 0 = 1 = 2 = 3 = 4 =

NONE DEUTSCH DEUTSCH 3 POS AMP 3 POS AMP & TAIL

LED/LENS COLOR 1 = 2 = 3 = 4 = 5 = A= B = G = R = D =

AMB/CLR BLU/CLR WHT/CLR GRN/CLR RED/CLR AMB/AMB

BLU/BLU GRN/GRN RED/RED WHT-RED/CLR

-AMB/AMB

BLU-WHT/CLR AMB-WHT/CLR BLU-RED/CLR AMB-RED/CLR

AMB-BLU/CLR BLU-BLU/CLR RED-RED/CLR

AMB-AMB/CLR RED-BLU/RED-BLU RED-WHT/RED-CLR

RED-AMB/RED-AMB

RED-RED/RED

BLU-BLU/BLUE AMB-AMB/AMB

E = F = J = K = M = 6 = 9 = 0 = 7 = 8 = W = V = T = S =

01-06864191 0_

700 LINEAR TIR STEADY 24V

SCREW, 6 X 1-1/2" PPHSMS SS

15-061416-240

SUB ASSY, REFLECTOR/LENS AMBER

02-036C168-A0

REFLECTOR, TIR

68-596B313-00

ASSY, PCB EXT FLASHER 24V AMBER

02-016C535-10

THERMAL INSULATOR

56-026123-000

HOUSING, HEATSINK W/ SEAL

11-46B358-S00

SCREW, 4 X 5/16 PPH SMS SS BLK / not shown

15-04521B-050

LABEL

10-0523566___

GASKET

38-0463342-00

FLANGE GROMMET, 700 SERIES

11-76D257-000

02-036C168-B0

02-036C168-C0

02-036C168-R0

SUB ASSY, REFLECTOR/LENS BLUE

SUB ASSY, REFLECTOR/LENS CLEAR

SUB ASSY, REFLECTOR/LENS RED

01-06864192 0_

700 LINEAR TIR STEADY 12V

01-06864192 1_

700 LINEAR TIR STEADY 12V DEUTSCH

01-06864193 2_

700 LINEAR TIR LOW POWER 24V DEUTSCH

02-036C168-G0

SUB ASSY, REFLECTOR/LENS GREEN

02-016C535-20

02-016C535-30

02-016C535-40

02-016C535-50

ASSY, PCB EXT FLASHER 24V BLUE

ASSY, PCB EXT FLASHER 24V WHITE

ASSY, PCB EXT FLASHER 24V GREEN

ASSY, PCB EXT FLASHER 24V RED

02-016C534-50

02-016C534-40

02-016C534-30

02-016C534-20

02-016C534-10

ASSY, PCB LOW POWER 24V RED

ASSY, PCB LOW POWER 24V GREEN

ASSY, PCB LOW POWER 24V WHITE

ASSY, PCB LOW POWER 24V BLUE

ASSY, PCB LOW POWER 24V AMBER

02-016C464-50

02-016C464-40

02-016C464-30

02-016C464-20

02-016C464-10

ASSY, PCB EXT FLASHER 12V RED

ASSY, PCB EXT FLASHER 12V GREEN

ASSY, PCB EXT FLASHER 12V WHITE

ASSY, PCB EXT FLASHER 12V BLUE

ASSY, PCB EXT FLASHER 12V AMBER

02-016C463-50

02-016C463-40

02-016C463-30

02-016C463-20

02-016C463-10

ASSY, PCB LOW POWER 12V AMBER

ASSY, PCB LOW POWER 12V RED

ASSY, PCB LOW POWER 12V GREEN

ASSY, PCB LOW POWER 12V WHITE

ASSY, PCB LOW POWER 12V BLUE

01-06864194 0_

01-06864194 1_

01-06864196 0_

700 LINEAR TIR LOW POWER 12V

700 LINEAR TIR LOW POWER 12V DEUTSCH

700 LINEAR TIR SYNC 12V

ASSY, PCB SYNC 12V BLUE

02-016C462-20

02-016C462-10

ASSY, PCB SYNC 12V AMBER

02-016C462-40

02-016C462-30

02-016C462-50

ASSY, PCB SYNC 12V GREEN

ASSY, PCB SYNC 12V WHITE

ASSY, PCB SYNC 12V RED

39-1H00326-35

SOCKET, DEUTSCH

39-1H02024-35

HOUSING, 2 POS SOCKET DEUTSCH

39-1H16424-2S

WEDGE, 2 POS SOCKET DEUTSCH

25-0910223-05

BUTT TAIL, 22-14 GAINS

ASSY, PCB SPLIT W/SL 12V AMBER/BLUE

02-016C526-12

02-016C526-11

ASSY, PCB SPLIT W/SL 12V AMBER/AMBER

02-016C526-55

02-016C526-35

02-016C526-33

02-016C526-25

02-016C526-23

02-016C526-15

02-016C526-13

02-016C526-22

ASSY, PCB SPLIT W/SL 12V RED/RED

ASSY, PCB SPLIT W/SL 12V WHITE/RED

ASSY, PCB SPLIT W/SL 12V WHITE/WHITE

ASSY, PCB SPLIT W/SL 12V BLUE/RED

ASSY, PCB SPLIT W/SL 12V BLUE/WHITE

ASSY, PCB SPLIT W/SL 12V AMBER/RED

ASSY, PCB SPLIT W/SL 12V AMBER/WHITE

ASSY, PCB SPLIT W/SL 12V BLUE/BLUE

01-06864195 0_

700 LINEAR TIR SPLIT W/SL 12V

02-036C168-D0

SUB ASSY, REFLECTOR/LENS RED/CLEAR

02-036C168-J0

SUB ASSY, REFLECTOR/LENS RED/BLUE

02-036C168-K0

SUB ASSY, REFLECTOR/LENS RED/AMBER

01-06864195 1_

700 LINEAR TIR SPLIT W/SL 12V DEUTSCH

39-1H16424-3S

39-1H03024-35

WEDGE, 3 POS SOCKET DEUTSCH

HOUSING, 3 POS SOCKET DEUTSCH

700 LINEAR TIR REMOTE SPLIT 12V

01-06864197 0_

02-016C470-11

ASSY, PCB REMOTE SPLIT 12V AMB/AMB

02-016C470-12

ASSY, PCB REMOTE SPLIT 12V AMB/BLU

02-016C470-15

ASSY, PCB REMOTE SPLIT 12V AMB/RED

02-016C470-22

ASSY, PCB REMOTE SPLIT 12V BLU/BLU

02-016C470-25

ASSY, PCB REMOTE SPLIT 12V BLURED

02-016C470-35

ASSY, PCB REMOTE SPLIT 12V WHT/RED

02-016C470-55

ASSY, PCB REMOTE SPLIT 12V RED/RED

01-06864194 2_

700 LINEAR TIR LOW POWER 12V DEUTSCH

01-06864193 0_

700 LINEAR TIR LOW POWER 24V

01-06864192 3_

700 LINEAR TIR STEADY 12V AMP

01-06864194 4_

700 LINEAR TIR LOW POWER 12V AMP&TAIL

A/R

39-0403013-04

39-0501316-04

HOUSING, 3 POS PIN AMP

PIN, AMP

01-06864195_4

700 LINEAR TIR SPLIT W/SL 12V AMP&TAIL

A/R

ITEM

PART NUMBER DESCRIPTION

QTY QTY QTY QTY

QTYQTYQTYQTYQTYQTYQTYQTYQTYQTYQTY

11 thru 52

2 thru 9

WIRE FUNCTIONS - SYNC 12V

(Use SYNC Pattern Table)

(No Flash Patterns available)

(Use Standard Pattern Table)

(No Flash Patterns available)

(Use Standard Pattern Table)

(Use SPLIT Pattern Table)

WIRE FUNCTIONS - STEADY 24V

WIRE FUNCTIONS - LOW POWER 24V

WIRE FUNCTIONS - STEADY 12V

WIRE FUNCTIONS - LOW POWER 12V

WIRE FUNCTIONS - SPLIT 12V

Power

Ground

SYNC

Scan-Lock

Power

Ground

Power

Ground

HI/LO Power

Scan-Lock

Power

Ground

Power

Ground

HI/LO Power

Scan-Lock

Power Power

Ground

Scan-Lock

Power

Power Ground 1 Ground 2

WIRE FUNCTIONS - SYNC 12V LED COLOR BLACK GREY WHT/VIO

WIRE FUNCTIONS - STEADY 24V LED COLOR BLACK/WHITE

WIRE FUNCTIONS - LOW POWER 24V LED COLOR BLACK/WHITE VIOLET WHT/VIO

WIRE FUNCTIONS - STEADY 12V LED COLOR BLACK

WIRE FUNCTIONS - LOW POWER 12V LED COLOR BLACK VIOLET WHT/VIO

WIRE FUNCTIONS - SPLIT 12V LED COLOR 1 LED COLOR 2 BLACK WHT/VIO

WIRE FUNCTIONS - SPLIT 24V

LED COLOR 1 WHITE/LED COLOR 2 BLACK WHITE/BLACK

(Use SYNC Pattern Table)

(No Flash Patterns available)

(Use Standard Pattern Table)

(No Flash Patterns available)

(Use Standard Pattern Table)

(Use SPLIT Pattern Table)

WIRING:

Page 3

Whelen 70A02SAR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual