Whelen 90AA5SAR User Manual

ENGINEERING COMPANY INC.

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

900 Series Linear-LED®

Dual Super-LED® Lighthead

Installation Guide:

Fax: (860) 526-4078 Internet: www.whelen.com Sales e-mail: autosale@whelen.com Canadian Sales e-mail: autocan@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.

• 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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Installation:

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

External Flasher Models: 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 WHELEN® sales representative for specific vehicle application.

Note: Make sure lighthead will not interfere with existing equipment or any items on the opposite side of the mounting surface.

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

2. Install the four supplied plastic grommets into the mounting holes then install rubber grommets (customer supplied) into the wire holes.

3. Using appropriately sized wires (minimum wire size - 18 AWG), extend the lighthead wires to their 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, #8 x 1-1/2” sheet metal screws.

Flasher Models:

Scan-Lock™: White-Violet Wire / This feature allows the user to

select from several available flash patterns TO CYCLE THROUGH ALL PATTERNS: Apply positive voltage to the WHITE-

VIOLET wire for less than 1 second and release to cycle forward. Apply positive voltage to the WHITE-VIOLET wire for more than 1 second and release to cycle backward.

TO SET A PATTERN AS DEFAULT: Allow the desired pattern to run for more than 5 seconds. The lighthead will now display this pattern when active.

7.26"

3.62"

1" diameter hole

2.62"

1/4" diameter hole (4 places)

1" diameter hole

5.24"

1.50"

TO RESET TO THE FACTORY DEFAULT PATTERN: Turn off power, apply positive voltage to the WHITE-VIOLET wire, then turn power on.

Available Flash Patterns: SignalAlert™75 / SignalAlert™150 / SingleFlash 375 / SingleFlash 150 / SingleFlash 75 / DoubleFlash 150 / DoubleFlash 75 CometFlash®75 / ActionFlash™ / ModuFlash™ / ComAlert™ / ActionScan™ / SignalAlert™ Steady / Steady (Brake)

Hi/Low Intensity: Violet Wire / 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 high power operation.

IMPORTANT WARNING!

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

WIRE FUNCTIONS - LO-POWER 12V LED COLOR BLACK VIOLET WHITE/VIOLET -

WIRE FUNCTIONS - STEADY 12V LED COLOR BLACK -

WIRE FUNCTIONS - LO-POWER 24V

BLACK/WHITE VIOLET WHITE/VIOLET -

WIRE FUNCTIONS - STEADY 24V LED COLOR BLACK/WHITE -

WIRE FUNCTIONS - EXTERNAL FLASHER 12V SOLID LED COLOR WIRE

Power (Upper Side 1)

BLACK - GROUND

WHITE/LED COLOR TRACE WIRE

Power (Upper Side 2)

WHITE/BLACK GROUND (Upper Side 2)

SOLID LED COLOR WIRE

Power (Lower Side 1)

BLACK - GROUND

(Lower Side 1)

WHITE/LED COLOR TRACE WIRE

Power (Lower Side 2)

WHITE/BLACK - GROUND

(Lower Side 2)

ower

Ground

Hi/Low Power

Scan-Lock™

owerP

Ground

owerLED COLOR -

round

H/L P

iowower

Scan-Lock™

Power

Ground

(Upper Side 1)

QTY QTY QTY QTY

4444

1411

PART NUMBER KEY: 01-0686408___

QTY

ITEM

PART NUMBER KEY: 01-0686409___

4414

PART NUMBER

01-0686409___

15-081416-240

38-0481690-00

21-1708080603

ITEM PART NUMBER DESCRIPTION

01-06864081__

01-06864083__

01-06864086__

01-06864088__

15-081416-240

38-0481690-00

21-1708080603

UPPER & LOWER LED COLORS

LENS COLOR STYLE/VOLTAGE

900 DUAL LINEAR TIR SPLIT

SCREW, 8 X 1-1/2" PPHSMS SS

GASKET

SCREW GROMMET, ROUND HOLE

LOWER LED COLOR UPPER LED COLOR LENS COLOR

LENS COLOR A=

AMBER

BLUE

CLEAR

RED

900 DUAL LINEAR TIR STEADY 24V

900 DUAL LINEAR TIR LOW POWER 24V

900 DUAL LINEAR TIR STEADY 12V

900 DUAL LINEAR TIR LOW POWER 12V

SCREW, 8 X 1-1/2" PPHSMS SS

GASKET

SCREW GROMMET, ROUND HOLE

STYLE/VOLTAGE 1=

STEADY/24V

LOW POWER/24V

STEADY/12V

LOW POWER 12V

LENS COLOR A=

AMBER

BLUE

CLEAR

GREEN

RED

UPPER LED COLOR A=

AMBER/AMBER

BLUE/BLUE

WHITE/RED

BLUE/RED

AMBER/RED

AMBER/BLUE

RED/RED

UPPER & LOWER LED COLORS K= E= D= J= P= M= A=B=AMB/AMB

DESCRIPTION

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

BLU/BLU

LOWER LED COLOR A= B= D= J= K= M= R=

WH /WH

GRN/GRN

RED/RED

AMB/WH

AMBER/AMBER BLUE/BLUE WHITE/RED BLUE/RED AMBER/RED

AMBER/BLUE

RED/RED

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