Whelen Engineering Company 800E-series User manual

Page 1
©2004 Whelen Engineering Company Inc.
Form No.13916A (012307)
Route 145, Winthrop Road,
Chester, Connecticut 06412
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]
Automotive: Beacons
Installation Guide:
800E-series Strobe Beacon
®
ENGINEERING COMPANY INC.
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 the 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 owners 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 (this does not include products that use cigar power cords).
• If this product uses a remote device for activation or control, make sure that this device is located in an area
that allows both the vehicle and the device 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!
For warranty information regarding this product, visit www.whelen.com/warranty

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Fig. 1
PERMANENT
MOUNT
"J" HOOK
MOUNT
The 800E Series Beacon has fully encapsulated electronics that
are impervious to damage from moisture and vibration. The LED
diagnostic indicator displays the operational state of the electronic
power supply and flash tube. The unit has an automatic photocell
“High Power Over-Ride”, a feature which can be overridden to
maintain high intensity during nighttime operation. This beacon
also features Scan-Lock™ which allows you to choose between 7
available flash patterns. You have 3 mounting options, permanent
mount, pipe mount and J-hook mount. The beacon features an
easily replacable snap-in flash tube and is SAE certified.
Specifications:
Model 800E Series: SAE class 1 (all colors) 12-24 VDC
Input Power: .................................................................... 37 watts
Output Power: ................................................26 watts / 22 joules
Input Current: ................................................. 2.9 amps / 12 VDC
......................................................................... 1.5 amps / 24 VDC
Note: All beacons in this manual should be fused at 5 AMPS.
WARNING!The strobe light power supply is a high voltage
device. Do not touch or remove the strobe tube or
assembly. Wait 10 minutes after disconnecting the
unit from power before starting any work or
trouble shooting on the power supply or system.
Note: The power readings listed above were taken with the
beacon operating in CometFlash®.
Wiring:
Listed below are the wire designations for the 800E beacon. Use
the wire gauge indicated below to extend the beacons wires.
WIRE COLOR. . . . . . . .WIRE GAUGE . . . . . . . . . . . FUNCTION
RED . . . . . . . . . . . . . . .18 AWG . . . . . . . . . . . . . . . . . . . Positive
BLACK . . . . . . . . . . . . .18 AWG . . . . . . . . . . . . . . . . . . . Ground
VIOLET . . . . . . . . . . . . .18 or 22 AWG . . . High Power Over-ride
WHITE-VIOLET . . . . . .18 or 22 AWG . . . . . . . . . . Scan-Lock™
Mounting:
1 INCH (NPT) PIPE MOUNT:
Threading for a 1 inch (NPT) pipe mounting is precast in the base.
1. Feed power cable through the 1 inch pipe and connect the
cable to the wires of the beacon.
2. Screw the beacon into the threads on the 1” pipe, taking
precaution not to damage the connected power wires. Do not
tighten base too hard as not to damage threads on base.
PERMANENT MOUNT:
1. Use the base as a template and mark the three mounting
holes off onto the mounting surface. After removing the base,
in the center between the three mounting holes, mark the
location of the wire access hole.
2. Drill mounting holes into the mounting surface with a drill
sized for the #10 mounting screws supplied. Drill the wire
access hole using a 3/8” drill (.375 inch). Remove any burrs
from the wire access hole as not to damage wires. It is also
recommended that you install a rubber grommet (customer
supplied) into the wire hole to further protect the wires.
3. The base seal (ITEM 12) will be used between the strobe
beacon base and the mounting surface.
4. Feed the wires first through the base seal and then through
the cable access hole and place the base (with seal) on the
mounting surface (while lining up the mounting holes in the
base with the mounting holes you drilled into the mounting
surface). Secure the beacon firmly to the mounting surface
with the supplied mounting screws (ITEM 10).
“J” HOOK MOUNT:
This beacon is equipped to handle the “J” hook mount available
on some beacons. Be sure to use the correct “J” hook mounting
holes (Fig. 1).
Operation:
Programming / Scan-Lock™ / White-Violet:
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 for more than 1 second and
release to cycle backward.
To set a pattern as default: When the desired pattern is
displayed, allow it to run for more than 5 seconds. The beacon will
now display this pattern when activated.
To reset to the factory default pattern: Turn off power. Now,
while applying Positive (+) voltage to the WHITE-VIOLET wire,
turn power back on.
Mounting Plan / Permanent Mount
5 - 15/16"
DIA. B.C.
3/8" DIA. WIRE
ACCESS HOLE
MTG. HOLES FOR #10
SCREWS / 3 HOLES EQ. SPACED

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ITEM 8 Sits on
the first ledg
e
13
9
WHITE-VIOLET: Scan-Lock™
RED: +12VDC
BLACK: GROUND
VIOLET: HI-LO POWER
68-2161803-V0
68-2161803-R0
68-2161803-G0
68-2161803-C0
68-2161803-B0
15-065419-080
38-0443007-00
36-0343008-00
15-101416-100
01-0263736-62
38-0241596-00
68-2161803-A0
01-0663937-_0
A/R
A/R
1
A/R
A/R
A/R
A/R
2
1
3
1
1
ASSY LENS - BLUE/
ASSY LENS - AMBER/
ASSY STROBE BEACON 800E SERIES/
ASSY LENS - VIOLET/
ASSY LENS - RED/
ASSY LENS - GREEN/
ASSY LENS - CLEAR/
SCREW #6 X 1/2 PPH PLASTI SS/
SCREW #10 X 5/8 PPHSMS/
ASSY BASE 26W CAST/
O-RING
SEAL BASE/
ASSY FLASHTUBE/
213-062C40-16J SCREW GROMMET
2
3
ITEM PART NUMBER DESCRIPTION
QTY
11
12
13
4
5
6
7
8
9
10
1
01-0683997-_0
LENS COLOR
A=
B=
AMBER
BLUE
CLEAR
GREEN
C=
G=
RED
VIOLET
R=
V=
7
56
34
12
8
12
11
10
Available Scan-Lock™ Patterns:
Comet Flash® (Default Pattern). . . . . . . . . . . . . . . . . . . 70 FPM
Triple Flash™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 FPM
Double Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 FPM
Single Flash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 FPM
ModuFlash™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-60 FPM
Action Flash™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Comet-Single
ScanFlash™. .Comet-Single-Triple-Single-Double-Single-Repeat
High Power Over-ride: Violet
This beacon is equipped with photocell Hi-Lo. This means the
beacon will automatically step down to low power at night. If you
wish to keep the beacon in high power at night, ground the
VIOLET wire. This will cause the beacon to stay in high power
until you remove the ground. In applications requiring SAE
compliance, this line should be permanently grounded.
LED Diagnostic Indicator:
This strobe beacon comes equipped with an LED diagnostic
indicator. If the flash tube does not light and the LED is blinking,
replace the flash tube. If the flash tube does not light and the LED
is not blinking, check the power wires, fuse or strobe power
supply. The LED is located under the lens (Fig. 2).
Replacing the Flashtube:
1. Remove the lens screws and remove the lens.
2. While pinching the 2 clips on the sides of the flastube
together, pull the old flash tube out of the beacon.
3. Plug the new flash tube into the base and replace the lens.
LED
INDICATOR
1. Remove
lens screws
4. Lift out old tube.
Fig. 2
Fig. 2
REMOVE
LENS
REMOVE
LENS
2. Remove
lens
Fig. 2
3. pinch pins together
to release tube from
base while lifting.