Whelen FNMINI User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684

Freedom™ Mini Edge® NFPA Lightbar

Installation Guide:

Phone: [phone]
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: Lightbars

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

©2003 Whelen Engineering Company Inc.
Form No.13781F (052410)

Page 1

IMPORTANT! The lightbar should be located a minimum of
16" from any radio antennas!

Permanent Mounting:

1. Locate the mounting foot and mounting plate included with your
lightbar. If not already present, install the mounting plate onto the
mounting foot. When properly positioned, this plate is centered from
side to side on the mounting foot.

2. Flip the lightbar upside-down to expose the bottom of the extrusion
and place the mounting foot onto the extrusion.

3. Rotate the mounting foot 90° in a counter-clockwise direction. Make
sure that the edges of the mounting foot swing into position under the
extrusion mounting lip.

4. Repeat this procedure for the remaining mounting foot and return the
lightbar to its right side-up position.

5. Position the lightbar onto the vehicle roof in the desired mounting
location. One often selected location is directly above the B-pillars.
This area is the strongest part of the roof. Refer to your lightbar
manual for cable exit location, to be sure that the lightbar is facing the
proper direction.

6. Adjust the two mounting feet outwards so that they are as close to
the edge of the roof as possible. Make sure that both mounting feet
are in full contact with the roof. Be sure that there is no less than 1/2”
clearance between the roof and the lightbar at their closest point.
When the mounting feet are in their proper position, lightly tighten the
mounting foot allen head set screws.

7. Turn the lightbar upside down and firmly tighten all of the set screws
from step 6 (2 or 4 per side).

8. Note that on the adjustable foot, use the hole in the pad as a guide to
drill the two holes into the mounting foot at the locations shown.

Standard
Mounting

BoltBolt

Mounting
Plate

Foot

Mounting
Plate

Nut

Washer

Mounting

Pad

Washer

Nut

Adjustable
Mounting

Mounting

Pad

9. Place the lightbar in its final mounting position on the vehicle, mark
the mounting hole locations off onto the mounting surface, remove
the lightbar and drill the mounting holes.

10. Place the lightbar back onto the vehicle lined up with the mounting
holes and secure the mounting feet to the vehicle using the supplied
hardware as shown.

Foot

Strap Mounting:

1. Locate the mounting foot, mounting plate and tinnerman plate
included with your lightbar. If not already present, install the mounting
plate onto the mounting foot. When properly positioned, this plate is
centered from side-to-side on the mounting foot.

2. Flip the lightbar upside-down to expose the bottom of the extrusion
and place the mounting foot onto the extrusion.

3. Rotate the mounting foot 90° in a counter-clockwise direction. Make
sure that the edges of the mounting foot swing into position under the
extrusion mounting lip. Install a tinnerman plate onto the extrusion in
the same manner.

Page 2

4. Repeat this procedure for the remaining mounting foot and tinnerman
plate and return the lightbar to its right side-up position.

5. Position the lightbar onto the vehicle roof in the desired mounting location.
One often selected location is directly above the B-pillars. This area is the
strongest part of the roof. Refer to your lightbar manual for cable exit
location, to be sure that the lightbar is facing the proper direction.

6. Adjust the two mounting feet outwards so that they are as close to the
edge of the roof as possible. Both mounting feet must be in full contact
with the roof. Be sure that there is no less than 1/2” clearance between
the roof and the lightbar at their closest point. When the mounting feet are
in their proper position, lightly tighten the mounting foot allen head set
screws.

7. Return the lightbar to an upside-down position. Slide each tinnerman
plate outwards until it is fully engaged with its corresponding mounting
foot. With the mounting feet and tinnerman plates in their proper positions
firmly tighten all of the set screws (2 or 4 per side). Flip the lightbar right
side-up and return it to its mounting position.

8. Open both drivers side doors. In the area directly below the mounting
foot, carefully pull the drivers side weatherstrip away from the vehicle.

Remove enough so that the area where the mounting strap will be
secured to the vehicle is exposed. Repeat procedure for passenger side.

9. Insert the mounting strap through the mounting foot. Be sure that the
strap fits flush against the area where it will be secured onto the vehicle.
Insert the tension bolt through the mounting strap and into the tinnerman
nut on the tinnerman plate. Tighten slightly with a long shafted, Phillips
screwdriver. Repeat procedure for passenger side.

10. If your mounting strap has mounting holes in the end of the strap, use
these holes as a template to drill appropriately sized pilot holes through
the strap and into the vehicle. Repeat for passenger side of the vehicle.

11. Firmly tighten the tension bolts to secure the lightbar to the vehicle.

NOTE: Model MKAJ is an adjustable mounting foot. On this model you
may loosen the screws on the rear of the foot and adjust the angle of the
lightbar. This feature can be used if the angle of the roof is not level with
the road.

IMPORTANT: To adjust the leveling screws you must use a torque wrench
set at 35 to 40 in./lbs.

Standard Mounting Foot / Model MKEZ

Mounting

Foot

Mounting
Strap

Tinnerman

Mounting

Plate

Plate

Tension

Bolt

Mounting

Mounting
Screw

Pad

5" Mounting Foot

METAL SCREW

BOLT

SHEET
METAL
SCREWS

STRAP

NOTE: The mounting straps are made to fit the contours of individual

vehicles. The strap

NOTE:

for your vehicle

NOTE:

shown here is for example only. The strap

may look different.

Tighten

with

set at 35

torque

MOUNTING FOOT

EXTENSION

NUT

SPLIT LOCK
WASHER

screws

wrench

to 40 in/lbs

TINNERMAN

NUT

FOOT

ANCHOR

PLATE

RO

VEHICLE

Plate slides into
lightbar extrusion

F

O

Mounting

Screw

SET
SCREW

Adjustable Mounting Foot / Model MKAJ

Mounting

Tension

Bolt

Adjustment

screws

Lock

Washer

Strap

Locking
Plate

Nut

Mounting
Foot

Mounting
Pad

Tinnerman
Plate

If your lightbar has a 5” mounting foot, it will assemble
differently than the standard mounting foot. It also uses an
extension to compensate for the extra height. Follow these
illustrations for assembly. Mounting to the lightbar is the
same.

IMPORTANT: For strap mounted bars, be sure you have the right sized
lightbar for your vehicle. The lightbar should be approximately the same
width as the vehicle roof. If too large or small it will not mount properly

1/2" MIN. CLEARANCE

NOTE: Unless otherwise specified, the lightbar mounting feet must be sitting as close to the edge of the roof as possible. They must also be
in full contact with the roof and not be hanging off the edge.

to the vehicle and may come loose during driving.

Page 3

CAUTION: Permanent mounting will require drilling. The installer must be
sure that no vehicle components or other vital parts will be damaged. Be
aware of the location of any front, side or upper air bags.

CAUTION: There may be a roof support member that spans the distance
between the driver’s and passenger’s side. Do not drill through this
member. Adjust the location of the cable access hole until the hole can be

with

DRILLING THE CABLE ACCESS HOLE

FRONT OF LIGHTBAR

For

lightbars

cables exiting

the Driver-side

of the extrusion

For

lightbars

cables exiting

with

the Passenger-side

of the extrusion

drilled without contacting this support member.

IMPORTANT! It is the responsibility of the installation technician to make
sure that the installation and operation of this product will not interfere with

Drill cable access hole in appropriate area

for your lightbar (see note)

or compromise the operation or efficiency of any vehicle equipment!

CAUTION: Using a magnetic mounted light on the outside of a vehicle, while in motion, is not recommended and is at the sole risk of the user.

Installation:

1. To protect the headliner from damage caused by drilling the cable access hole through the vehicle roof, allow a 5” to 7” distance between roof and
headliner by lowering the headliner before drilling.

2. Using a 1” hole saw, drill the cable access hole. Use a round file to smooth and de-burr the edges and insert a 1” grommet (user supplied).

3. Insert the cable(s) through the cable access hole into the vehicle. Use RTV silicone to weatherproof the access hole after the cable(s) are pulled into
the vehicle.

4. When routing the cable(s), be sure to use a path that avoids any vehicle components or other vital parts that may be damaged. Also be careful not to
interfere with any vehicle air bags (front, side, etc.). Route the cable(s) towards your switch panel and refer to the instructions included with the
switch panel for wiring information.

Wiring:

Your lightbar has reverse polarity protection. If the lightbar will not turn on,
you may have blown an internal fuse. (See drawing on next page for fuse
location.) To replace it you have to disassemble the lightbar. (See last
page for assembly-disassembly instructions.)

This lightbar is equipped with an 11-conductor cable, the wire function
chart below, gives: wire color, function, voltage to apply to activate the
function, and how many Amps to fuse the wire at.

COLOR / VOLTAGE FUNCTION FUSE @

RED / +12VDC LED Flasher (+) Positive ................5 Amps

BLK-YEL / +12VDC .........(+) Scan-Lock™ ...............................1 Amp

GRY / +12VDC.................Front Corner LEDs ............................1Amp

WHT / +12VDC ................Halogen 1 (Optional) ......................5 Amps

WHT-BLK / +12VDC ........Inboard LEDs .................................5 Amps

YEL / +12VDC..................Halogen 2 (Optional) ......................5 Amps

WHT-BLU / +12VDC ........Rear Corner LEDs (Optional) ...........1 Amp

BLK-WHT / Ground.........Halogen 1 & 2 (-) Ground (Optional) .... N/A

WHT-VIO / +12VDC .........Endcap LEDs ...................................1 Amp

VIO / +12VDC ..................Low Power........................................1 Amp

BLACK / Ground.............LED Flasher (-) Ground........................ N/A

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 that

load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

Hi/Low Control:

The type of switch used is dependant on how the operator wishes
the Hi/Low feature to function:

Option 1: Latching Mode: By applying +voltage to the VIOLET wire for

less than 1 sec., the power supply is “latched” into low power operation.
The unit must be turned off and then back on to restore normal, Hi power
operation. A momentary switch is best for this method.

Option 2: Level Mode: Applying +voltage to the VIOLET wire for more
than 1 sec. holds the power supply in low power mode until that voltage is
removed. A toggle switch is best for this method.

Scan-Lock™:

To cycle forward through all patterns: Apply power to the control wire

of the function you want to change, then apply power to the BLACK­YELLOW (Scan-Lock) wire for less than 1 second and release. This will
change the pattern. Repeat for next pattern.

To choose a pattern: While cycling through the patterns, when you find
the pattern you want let it run for more than 5 seconds and it will lock in
and become the default pattern.

To reset to the factory default pattern: Turn off power, apply power to
the Scan-Lock wire and the wire of the function you want to reset, then
turn power back on.

Scan-Lock can be connected to a customer supplied SPST switch.

Corners / Cross

Corners / Alternating

1A SignalAlert™ . . . . . . . . . .Alternating

1B SignalAlert™ . . . . . . . . . . . . . Cross

1C SignalAlert™ . . . . . . . 3 cycles of 1A

. . . . . . . . . . . . . . . . . . . & 3 cycles of 1B

2A CometFlash® . . . . . . . . . .Alternating

2B CometFlash® . . . . . . . . . . . . . Cross

2C CometFlash® . . . . . . . 3 cycles of 1A

. . . . . . . . . . . . . . . . . . . & 3 cycles of 1B

3A DoubleFlash. . . . . . . . . . .Alternating

3B DoubleFlash. . . . . . . . . . . . . . Cross

3C DoubleFlash. . . . . . . . 3 cycles of 1A

. . . . . . . . . . . . . . . . . . . & 3 cycles of 1B

4A SingleFlash . . . . . . . . . . .Alternating

4B SingleFlash . . . . . . . . . . . . . . Cross

4C SingleFlash . . . . . . . . 3 cycles of 1A

. . . . . . . . . . . . . . . . . . . & 3 cycles of 1B

6 SteadyFlash . . . . . . . . . 1 & 2 Steady

. . . . . . . . . . . . . 3 & 4 SingleFlash (SIM.)

7 Steady . . . . . . . . . . 1, 2, 3 & 4 Steady

Page 4

DRIVER'S SIDE PASSENGER'S SIDE

RED LED

RED LED

10

FUSE

DUMMY LIGHTHEAD

234

Driver Side
(Reference)

1

WHITE LED

FRONT OF
LIGHTBAR

10

FUSE

RED LED

RED LED

AB

5

6

DUMMY LIGHTHEAD

7

ITEM

QTY

4

4

6

2

2

4

4

4

4

01-0684222-36

02-0364528255

12

01-0263814-50

2

68-1983817-30

3

02-0341448-30

4

5

68-1983816-30

02-0364528233

6

38-0283381-00

7

68-1183369-30

8

68-5983915-01

9

68-1984104-30

10

AB

DUMMY LIGHTHEAD

PART NUMBER DESCRIPTION

WHITE LED

FRONT OF
LIGHTBAR

10

FUSE

NFPA Freedom™Mini, 4-LEDs, Perm Mount (Pair)

400 LED (SPLIT) RED/RED

LED CORNER LINEAR (RED)

LENS (CLEAR) 6.562”

LENS DIVIDER (CLEAR)

LENS (CLEAR) 5.000”

400 LED (SPLIT) WHT/WHT

ENDCAP GASKET

ENDCAP (CLEAR)

CORNER FILLER

LENS (CLEAR) 9.250”

RED LED

DUMMY LIGHTHEAD

10

FUSE

RED LED

10 9

WIRE COLOR & VOLTAGE

8

FUNCTION FUSE @

RED / +12VDC ................................LED Flasher (+) Positive................................ 5 Amps

BLACK-YELLOW / +12VDC........... (+) Scan-Lock™.............................................1 Amp

GRAY / +12VDC..............................Front Corner LEDs......................................... 1 Amp

WHITE / +12VDC ............................Halogen 1 (Optional)......................................5 Amps

WHITE-BLACK / +12VDC...............Inboard LEDs .................................................5 Amps

YELLOW / +12VDC.........................Halogen 2 (Optional)...................................... 5 Amps

WHITE-BLUE / +12VDC .................Rear Corner LEDs (Optional).........................1 Amp

BLACK-WHITE (-)...........................Halogen 1 & 2 (-) Ground (Optional) ............. N/A

WHITE-VIOLET / +12VDC ..............Endcap LEDs .................................................1 Amp

VIOLET / +12VDC...........................Low Power .....................................................1 Amp

BLACK / Ground ............................ LED Flasher (-) Ground ................................. N/A

Page 5

Note: Should you need to service or repair your lightbar, the diagrams below will show you how to gain access.

Installing Endcap Gasket & Alley Light

Place the endcap gasket into position on the endcap, locating all tabs and holes. Align the reflector assembly of the alley light with
the 4 bosses in the endcap and press the reflector in place until the 4 barbs engage around the reflector.

LIGHTHEAD

BARB

BOSS

GASKET

Lighthead Mounting Bracket

EXTRUSION

Ears on mounting
bracket slide into
the channels in
the extrusion.

Lighthead mounting
holes snap into the
raised bosses on
mounting bracket.

LIGHTHEAD

Installing a Corner LED

TOP VIEW OF EXTRUSION END VIEW OF EXTRUSION

Snap lighthead into bracket here

Passenger

CORNER LED

CENTER OF EXTRUSION

Extrusion

Front

Slide Spacer in here

Removing the Endcap and Lenses

Remove the four screws (A) that hold the endcap on and pull
the endcap and gasket (C) off.

Slide the lenses (D) out of the
lightbar, to gain access to the extrusion. When reinstalling
the endcap, first place the gasket into position on the
endcap. Be sure to line up all the tabs and holes
on the gasket.

(B)

D

Lighthead Tabs
slide into extrusion

Front

Passenger

The edge of the lighthead snaps into the
clips on the mounting bracket.

C

A

B

Page 6