Whelen 70C00VCR User Manual

ENGINEERING COMPANY INC.

51 Winthrop Road Chester, Connecticut 06412-0684

700 Series LED Lighthead

Installation Guide:

Phone: (860) 526-9504 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

Page 1

CAUTION! DO NOT LOOK DIRECTLY AT THESE LEDS WHILE THEY ARE ON. MOMENTAR Y BLINDNESS AND/OR EYE DAMAGE COULD RESULT!

IMPORTANT WARNING!

IMPORTANT NOTICE!This product has been designed for improved visibility. Prior to installing

3.281"

6.562"

5/16"

Diameter

Vent Hole

1.187"

1.68"

.84"

2.375"

700 SERIES LED LIGHTHEAD

MOUNTING DIMENSIONS

NOT TO SCALE / FOR MEASUREMENTS ONLY

1/4" Mounting Hole / 4 Places

1" Wire Hole

this product on any vehicle, check your state motor vehicle codes to confirm that this product complies with any and all state statutes.

Mounting:

1. Using the dimensions below, mark off and drill the two, 5/16” diameter vent tube holes and the 1” wire hole into the mounting surface. Make sure lighthead will not interfere with existing equipment and be aware of any items on the opposite side of the mounting surface.

IMPORTANT WARNING: Always check all measurements before drilling. Measurements are given in both decimals and fractions for your convenience. For a more accurate measurement and installation, use the decimals.

2. Insert the two vent tubes extending from the rear of the lighthead into their holes. Using a scribe or similar tool, mark off the 4 mounting holes.

3. Using a 1/4” drill bit, drill the four mounting holes. Install a grommet (customer supplied) into the 1” wire hole.

4. Using appropriately sized wires (minimum 18 AWG wire size), extend the lighthead wires to their connections (see “Wiring Options”). Fuse the +12VDC connections at 3 Amps and test the lighthead before securing it to the vehicle.

Note:Some 700 series lightheads are equipped with the SYNC feature. These lightheads will have an extra grey wire (See below).

5. Position the lighthead components onto the mounting surface and secure to the vehicle using the flange grommet and four supplied #6 x 1-1/4” sheet metal screws.

WARNING! 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.

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 at the battery to carry the load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

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

This product draws significantly less current than a standard incandescent

Specifications:

BRAKE/TAIL/TURN LED Assembly - 120 LEDs (MAX)

Input Voltage - 12.8 VDC ±20% Input Current - Tail - 0.125 Amps

Default Pattern - SignalAlert™ Brake

LED Assembly - 56 LEDs (MIN) Input Voltage - 12.8 VDC ±20% Input Current - Tail - 0.075 Amps

Default Pattern - SignalAlert™ Brake

WIDE ANGLE WARNING Input Voltage - 12.8 VDC ±20%

Input Current - 0.40 Amps (Blue / White / Green)

Default Pattern - RapidFire™ 375

TURN Input Voltage - 12.8 VDC ±20%

Input Current - 0.70 Amps Default Pattern - SignalAlert™ Brake

BACK-UP (12V) Input Voltage - 12.8 VDC ±20%

Input Current - 0.300 Amps Default Pattern - Steady On

BACK-UP (24V) Input Voltage - 25.6 VDC ±20%

Input Current - 0.150 Amps Default Pattern - Steady On

ARROW Input Voltage - 12.8 VDC ±20%

Input Current - 0.475 Amps Default Pattern - Steady

DUAL COLOR Input Voltage - 12.8 VDC ±20%

Input Current - 0.475 Amps Default Pattern - RapidFire™ 680

SYNC Input Voltage - 12.8 VDC ±20%

Input Current - 0.475 Amps Default Pattern - SignalAlert™ (Simultaneous)

- Brake - 0.70 Amps

- Brake - 0.375 Amps

- 0.45 Amps (Amber / Red)

Flash Pattern Synchronization (SYNC):

A SYNC feature is available on selected models. This allows two (or more) lightheads to flash the same, synchronized pattern in either simultaneous or alternating mode. In order to enable SYNC mode, it is necessary for the GREY wires from each lighthead to be connected together.

There is only one pattern available to a SYNC-capable lighthead, offering both a simultaneous and alternating mode:

SignalAlert™ 75 Simultaneous mode - 75 fpm (Factory Default) SignalAlert™ 75 Alternating mode - 75 fpm

To help understand how to use SYNC, 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.

With all the wiring complete, turn on the 4 lightheads. As shipped from the factory, all the lightheads will be flashing simultaneously.

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 Alternating.

Important! SYNC-capable LED lightheads can be SYNCed to SYNCcapable strobe power supplies (such as the CS240S) by wiring their grey wires together. When connected as such, LED lightheads in their default pattern (simultaneous) will flash simultaneously with strobe lightheads connected to the GREEN wire outputs. LED lightheads configured for the alternating pattern will flash simultaneously with strobe lightheads connected to the WHITE wire outputs. GREEN wire outputs always alternate with WHITE wire outputs.

Page 2

Scan-Lock™ (White/Violet)

See next page for parts listings.

ARROW

..........

...Ground

....Scan Lock

LED Color Black(12V

) or

Black-White(24V

)

White-Violet - ™

Positive(+

)

NOTE: In some instances two ground wires are shown for reference. This is to show both the 12 volt and 24 volt models. The lighthead will have either one or the other depending on model.

..........Positive(+

)

............................SYNC

...............

Ground

SYNC LED Color Grey Black(12V

)

BRAKE-TAIL-TURN

....Brake Positive(+

)

........Tail Positive(+

)

...Ground

.....Scan Lock

Yellow / Brown / White(12V

) or

White-Black(24V

)

White-Violet - ™

..........Positive(+

)

...Ground

.....Scan Lock

TURN LED Color Black(12V

) or

Black-White(24V

)

White-Violet - ™

.......Positive(+

)

.......Positive(+

)

........................Ground

SPLIT LED Color 1 LED Color 2 Black

MAX BIAS

..........Positive(+

)

...Ground

LED Color Black(12V

) or

Black-White(24V

)

FLOOD or BACK-UP

..................Positive(+

)

...Ground

White Black(12V

) or

Black-White(24V

)

..........Positive(+

)

..Ground

......Scan Lock

WIDE ANGLE LED Color Black(+12V

) or

Black-White(24V

)

White-Violet - ™

2 3 4

58 64

26144516341836

284029

59 65

3317351937

10 11 399

7 85 6

21 23 25 41 4322 24 30 42 46 6150 6349 6257 66

51 53 54

Housing (w/studs): Housing: Mounting Hardware & Gasket:

11-483530-011

11-483530-111

01-0483596-00

For use with: HALOGEN, STROBE or LED lightheads

Lighthead Housing: Drivers Side: Passengers Side:

01-0462735-01

01-0462736-01

For use with: HALOGEN, STROBE or LED lightheads

Surface Mount Housing: Black: Chrome:

01-0464758-00

01-0464758-01

For use with: HALOGEN, STROBE or LED lightheads

Available Mounting Options

Wiring Options

Parts

Housing: Housing w/Studs: Mounting Hardware & Gasket:

11-463255-011

11-463255-111

01-0463331-00

Mini-Grill-Master Housing: Black: Chrome:

01-0483777-01

01-0483777-02

For use with: STROBE or LED lightheads

For use with: LED lightheads

Flange Kit: Without Seal With Seal

01-0462920-00

01-0462920-01

Swivel Mount Kit: Black: Chrome:

11-481138-00

01-0441293-00

WARNING: Pattern selection requires the LEDs to be turned on. Do not look directly at the LEDs while the unit is on.

TO CHANGE PATTERNS: Apply +VBAT to the WHITE/VIOLET wire for less

than 1 second and release to cycle forward to the next available pattern. Apply +VBAT to the WHITE/VIOLET wire for more than 1 second and release to cycle back to the previous pattern. Allow the pattern to run for more than 5 seconds to set as the default pattern.

TO RESTORE FACTORY DEFAULT PATTERN: With the power to the lighthead off, apply +VBAT to the WHITE/VIOLET wire. Now turn power to the lighthead on. The factory default pattern should now be displayed.

A Normally Open momentary switch can be used to control Scan-Lock.

IMPORTANT SPLIT LED NOTE: This lighthead will not have a Scan-Lock™ wire. You will find 2 sets of programming pins protruding from the LED side of the circuit board. Where the Scan-Lock instructions say “apply +12 volts to the Scan-Lock wire”, short the pins out with a penny (or other electrical conducting item). For a Split SMT LED lighthead, there will be 2 sets of programming pins. Both sides can be programmed separately using the same procedure as a regular LED lighthead.

Flash Patterns:

1. SignalAlert™ 75

2. SignalAlert 150

3. SingleFlash 375

4. SingleFlash 150

5. SingleFlash 75

6. SingleFlash 150

7. DoubleFlash 150

8. DoubleFlash 75

9. CometFlash® 75

10. ActionFlash™

11. ModuFlash™

12. ComAlert™

13. ActionScan™

14. SignalAlert Steady

15. Steady (Brake)

Brake Patterns:

1. SignalAlert Steady

2. Steady Brake

SYNC Patterns:

1. SignalAlert 75 (Sim.)

2. SignalAlert 75 (Alt.)

Arrow Patterns:

1. Seq. to Solid 150

2. Seq. to Solid 80

3. Seq. to Solid (Steady On - Fast)

4. Seq. to Solid (Steady On - Slow)

5. SignalAlert to Steady On

6. Steady On

Dual Color Patterns:

1. SingleFlash 680 (Alt.)

2. SingleFlash 240 (Alt.)

3. SingleFlash 120 (Alt.)

4. SingleFlash 150 (Sim.)

5. DoubleFlash 240 (Alt.)

6. DoubleFlash 120 (Alt.)

7. DoubleFlash 150 (Sim.)

8. CometFlash® 120 (Alt.)

9. CometFlash 120 (Sim.)

10. ActionFlash (Alt.)

11. ActionFlash (Alt. - Sim.)

12. ModuFlash (Alt.)

13. ModuFlash (Sim.)

14. SignalAlert 120 (Alt.)

15. SignalAlert 100 (Sim.)

16. ActionScan (Alt. - Sim.)

17. Action Single

18. CH.1 Steady-CH.2 SF120

19. CH.1 Steady-CH.2 Action Single

20. CH.1 Steady-CH.2 CometFlash

21. CH.1 Steady-CH.2 FastAction

Page 3

TERMINATION 0 = 1 = 2 =

NONE DEUTSCH AMP PIMS WITH 3 PIN CONNECTOR SHIPPED SEPERATELY

2 = 2 = 2 =

PART NUMBER KEY:

STYLE

TERMINATION

01-0683718___

STYLE 2 = 3 = 4 = 5 = 6 = 7 = B =

S = A= L= K = D = N =

B-T-T / MIN ARROW TURN WIDE ANGLE / SPLIT FLOOD BACK-UP

B-T-T / MAX 24V B-T-T / MAX BACK-UP (24V)

SYNC MAX BIAS TURN (24V)

WIDE ANGLE (24V)

MAX BIAS (24V)

B-T-T (CERTIFIED)

E = G =

LED-LENS COLOR A= B = C = G = R = D = J = 1 = 2 = 4 = 5 =

= W = 6 = 7 = 8 =

AMBER-AMBER BLUE-BLUE WHITE-CLEAR GREEN-GREEN RED-RED

RED-WHT / RED-CLR RED-BLUE / RED-BLU AMBER-CLEAR BLUE-CLEAR GREEN-CLEAR RED-CLEAR AMB-AMB-AMB RED-AMB / RED-AMB

RED / RED / RED AMB / AMB / CLEAR RED / AMB / CLEAR RED / RED / CLEAR

S K

LED/LENS COLOR

68-1183582-5S

LENS, RED OPTIC W/ SEAL

68-1183582-4S

LENS, GREEN OPTIC W/ SEAL

68-1183582-3S

LENS, CLEAR OPTIC W/ SEAL

68-1183582-2S

LENS, BLUE OPTIC W/ SEAL

68-1183582-1S

LENS, AMBER OPTIC W/ SEAL

LIGHTHEAD 700 LED WIDE ANGLE

01-06837185_0

01-06837182R0

01-0683718BR0

01-06837184_0

01-06837186C_

01-06837187C_

01-06837183__

LIGHTHEAD 700 LED TURN

LIGHTHEAD 700 LED FLOOD - WHITE

LIGHTHEAD 700 LED BACK-UP - WHITE

LIGHTHEAD 700 LED ARROW

LIGHTHEAD 700 LED BRAKE/TAIL/TURN (MIN) - RED

LIGHTHEAD 700 LED BRAKE/TAIL/TURN (MAX) - RED

15-061416-240

68-3183573-1S

68-3183573-3S

68-3183573-5S

02-0363417RBS

01-0283461-52

01-0283461-15

01-0283461-25

01-0283461-45

01-0283461-55

01-0283461-5B

01-0283461-35

01-0283461-14

01-0283461-54

01-0283461-36

01-0283461-37

01-0283461-13

01-0283461-53

01-0283461-J5

38-0463342-00

10-0522894___

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

LENS, AMBER W/ SEAL

LENS, CLEAR W/ SEAL

LENS, RED W/ SEAL

LENS, RED/BLUE OPTIC W/ SEAL

SUB ASSY, 700 LED BRAKE/TAIL/TURN (MIN)

SUB ASSY, 700 LED WIDE ANGLE - AMBER

SUB ASSY, 700 LED WIDE ANGLE - BLUE

SUB ASSY, 700 LED WIDE ANGLE - GREEN

SUB ASSY, 700 LED WIDE ANGLE - RED

SUB ASSY, 700 LED BRAKE/TAIL/TURN (MAX)

SUB ASSY, 700 LED WIDE ANGLE - WHITE

SUB ASSY, 700 LED TURN - AMBER

SUB ASSY, 700 LED TURN - RED

SUB ASSY, 700 LED FLOOD - WHITE

SUB ASSY, 700 LED BACK-UP - WHITE

SUB ASSY, 700 LED ARROW - AMBER

SUB ASSY, 700 LED ARROW - RED

SUB ASSY, 700 LED WIDE ANGLE - RED/BLUE

GASKET

LABEL, 700 SERIES LED LIGHTHEAD

02-0363417RCS

LENS, RED/CLEAR OPTIC W/ SEAL

01-0283461-D5

01-06837185_1

01-0683718BR1

LIGHTHEAD 700 LED BRAKE/TAIL/TURN (MAX) - RED/DEUTSCH

LIGHTHEAD 700 LED WIDE ANGLE - DEUTSCH

02-0383461115

02-038346115B

SUB ASSY, 700 LED WIDE ANGLE - AMBER/DEUTSCH

SUB ASSY, 700 LED BRAKE/TAIL/TURN (MAX) - RED/DEUTSCH

LIGHTHEAD 700 LED SYNC

01-0683718S_0

01-0283461-1S

SUB ASSY, 700 LED SYNC - AMBER

01-0283461-5S

SUB ASSY, 700 LED SYNC - RED

01-0283461-2S

SUB ASSY, 700 LED SYNC - BLUE

01-0283461-3S

SUB ASSY, 700 LED SYNC - WHITE

01-0283461-4S

SUB ASSY, 700 LED SYNC - GREEN

01-0283461-A5

SUB ASSY, 700 LED SPLIT - AMBER/AMBER

01-0283461-K5

SUB ASSY, 700 LED SPLIT - RED/AMBER

01-0283461-R5

SUB ASSY, 700 LED SPLIT - RED/RED

LENS, RED/AMBER OPTIC W/ SEAL

02-0363417RAS

02-0383461125

SUB ASSY, 700 LED WIDE ANGLE - BLUE/DEUTSCH

LIGHTHEAD 700 LED BRAKE/TAIL/TURN (MIN) - RED/DEUTSCH

01-06837182R1

02-0383461152

SUB ASSY, 700 LED B-B-T (MIN) - RED/DEUTSCH

SUB ASSY, 700 LED WIDE ANGLE - RED/WHITE

SUB ASSY, 700 LED FLOOD - WHITE/DEUTSCH

02-0383461136

01-0683718E__

LIGHTHEAD 700 LED 24V BRAKE/TAIL/TURN (MAX) - RED

SUB ASSY, 700 LED 24V BRAKE/TAIL/TURN (MAX)

01-0283461-5E

02-0383461137

SUB ASSY, 700 LED BACK-UP - WHITE/DEUTSCH

02-038346113G

SUB ASSY, 700 LED 24V BACK-UP - WHITE/DEUT

02-038346115E

SUB ASSY, 700 LED 24V B-T-T (MAX) - RED/DEUTSCH

01-0683718A_0

01-0683718L_0

01-0683718K__

01-0683718D_0

LIGHTHEAD 700 LED MAX BIAS

LIGHTHEAD 700 LED TURN 24V

LIGHTHEAD 700 LED WIDE ANGLE 24V

LIGHTHEAD 700 LED MAX BIAS 24V

SUB ASSY, 700 LED MAX BIAS - AMBER

01-0283461-1A

01-0283461-5A

SUB ASSY, 700 LED MAX BIAS - RED

01-0283461-1L

SUB ASSY, 700 LED TURN 24V - AMBER

01-0283461-5L

SUB ASSY, 700 LED TURN 24V - RED

01-0283461-1K

SUB ASSY, 700 LED WIDE ANGLE 24V - AMBER

01-0283461-5K

SUB ASSY, 700 LED WIDE ANGLE 24V - RED

01-0283461-1D

SUB ASSY, 700 LED MAX BIAS 24V - AMBER

01-0283461-5D

SUB ASSY, 700 LED MAX BIAS 24V - RED

01-0683718GC1

LIGHTHEAD 700 LED 24V BACK-UP - WHITE/DEUTSCH

02-038346115K

02-038346111K

SUB ASSY, 700 LED WIDE ANGLE 24V - AMB/DEUTSCH

SUB ASSY, 700 LED WIDE ANGLE 24V - RED/DEUTSCH

01-0683718NR0

LIGHTHEAD 700 LED B/T/T CERTIFIED

01-0283461-5N

SUB ASSY, 700 LED B/T/T CERTIFIED - RED

SUB ASSY, 700 LED ARROW - AMBER/DEUTSCH

02-0383461153

02-0383461113

SUB ASSY, 700 LED ARROW - RED/DEUTSCH

39-0403013-04

HOUSING, 3 POS. PIN, AMP

02-038346155B

02-0383461552

02-0383461537

02-0383461514

02-0383461513

02-03834615_5

SUB ASSY, 700 LED B-T-T(MAX) AMP PINS ONLY

SUB ASSY, 700 LED (MIN) AMP PINS ONLYB-T-T

SUB ASSY, 700 LED BACK UP, WHT AMP PINS ONLY

SUB ASSY, 700 LED TURN, AMP PINS ONLY

SUB ASSY, 700 LED ARROW, AMP PINS ONLY

SUB ASSY, 700 LED WIDE ANGLE, AMP PINS ONLY

01-0683718BR2

LIGHTHEAD 700 LED BRAKE/TAIL/TURN (MAX) - AMP PINS

LIGHTHEAD 700 LED BRAKE/TAIL/TURN (MIN) - AMP PINS

LIGHTHEAD 700 LED BACK UP - WHITE, AMP PINS

LIGHTHEAD 700 LED TURN, AMP PINS

LIGHTHEAD 700 LED ARROW,AMP PINS

LIGHTHEAD 700 LED WIDE ANGLE - AMP PINS

01-06837182R2

01-06837187C2

01-06837184A2

01-06837183A2

01-06837185_2

11-76D257-000

A/R

FLANGE GROMMET, 700 SERIES

A/R

ITEM

DESCRIPTION

QTY QTY QTY QTYQTYQTYQTYQTYQTYQTYQTYQTYQTYQTYQTYQTYQTYQTYQTY QTY QTY QTYQTYQTY

PART NUMBER

Page 4

Whelen 70C00VCR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual