Whelen Engineering Company HELS Lighthead User manual

Page 1
Installation Manual:
HELS™ Lighthead
©2003 Whelen Engineering Company Inc.
Form No.13770C (032408) For warranty information regarding this product, visit www.whelen.com/warranty
• Proper installation of this product requires the installer to have a good understanding of automotive electronics, systems and procedures.
• Whelen Engineering requires the use of waterproof butt splices and/or connectors if that connector could be exposed to moisture.
• Any holes, either created or utilized by this product, should be made both air- and watertight using a sealant recommended by your vehicle
manufacturer.
• 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 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 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 (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!
Automotive: Lightheads
Warnings to Installers
Whelen’s emergency vehicle warning devices must be properly mounted and wired in order to be effective and safe. Read and follow all of Whelen’s written
instructions when installing or using this device. Emergency vehicles are often operated under high speed stressful conditions which must be accounted for
when installing all emergency warning devices. Controls should be placed within convenient reach of the operator so that they can operate the system without
taking their eyes off the roadway. Emergency warning devices can require high electrical voltages and/or currents. Properly protect and use caution around
live electrical connections.Grounding or shorting of electrical connections can cause high current arcing, which can cause personal injury and/or vehicle
damage, including fire. Many electronic devices used in emergency vehicles can create or be affected by electromagnetic interference. Therefore, after
installation of any electronic device it is necessary to test all electronic equipment simultaneously to insure that they operate free of interference from other
components within the vehicle. Never power emergency warning equipment from the same circuit or share the same grounding circuit with radio
communication equipment. All devices should be mounted in accordance with the manufacturer’s instructions and securely fastened to vehicle elements of
sufficient strength to withstand the forces applied to the device. Driver and/or passenger air bags (SRS) will affect the way equipment should be mounted. This
device should be mounted by permanent installation and within the zones specified by the vehicle manufacturer, if any. Any device mounted in the deployment
area of an air bag will damage or reduce the effectiveness of the air bag and may damage or dislodge the device. Installer must be sure that this device, its
mounting hardware and electrical supply wiring does not interfere with the air bag or the SRS wiring or sensors. Mounting the unit inside the vehicle by a
method other than permanent installation is not recommended as unit may become dislodged during swerving; sudden braking or collision. Failure to follow
instructions can result in personal injury. Whelen assumes no liability for any loss resulting from the use of this warning device. PROPER INSTALLATION
COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF EMERGENCY WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF
EMERGENCY PERSONNEL AND THE PUBLIC.
Warnings to Users
Whelen’s emergency vehicle warning devices are intended to alert other operators and pedestrians to the presence and operation of emergency vehicles and
personnel. However, the use of this or any other Whelen emergency warning device does not guarantee that you will have the right-of-way or that other
drivers and pedestrians will properly heed an emergency warning signal. Never assume you have the right-of-way. It is your responsibility to proceed safely
before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around traffic lanes. Emergency vehicle warning
devices should be tested on a daily basis to ensure that they operate properly. When in actual use, the operator must ensure that both visual and audible
warnings are not blocked by vehicle components (i.e.: open trunks or compartment doors), people, vehicles, or other obstructions. It is the user’s responsibility
to understand and obey all laws regarding emergency warning devices. The user should be familiar with all applicable laws and regulations prior to the use of
any emergency vehicle warning device. Whelen’s audible warning devices are designed to project sound in a forward direction away from the vehicle
occupants. However, because sustained periodic exposure to loud sounds can cause hearing loss, all audible warning devices should be installed and
operated in accordance with the standards established by the National Fire Protection Association.
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.
WARNING: This product can expose you to chemicals including Methylene Chloride which is known to the State of California to cause cancer, and
Bisphenol A, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to
www.P65Warnings.ca.gov.
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Customer Service e-mail: [email protected]
®
ENGINEERING COMPANY INC.

Page 2
CAUTION! DO NOT LOOK DIRECTLY AT THESE LEDS WHILE THEY ARE ON.
MOMENTARY BLINDNESS AND/OR EYE DAMAGE COULD RESULT!
IMPORTANT WARNING!
PHASE 1
LEFT
RIGHT
side lights up and
with side.alternates
PHASE 2
RIGHT
LEFT
side lights up and
with side.alternates
PHASE 3
BOTH sides flash together
(ON-OFF-ON).
PHASE 4
BOTH sides flash together
(OFF-ON-OFF).
Note: Phases 3 & 4 are visually indistinguishable.
then
then OFF
ON
ON
ON
OFF
OFF
then
then ON
OFF ON
OFF ON
OFF
then
then ON ON
OFF OFF
OFF OFF
then
then OFF
ON
ON
ON
ON
OFF
STROBE VERSION SHOWN
FOR REFERENCE ONLY
Mounting:
WARNING! Strobe light power supplies are high voltage devices. Do not
touch or remove the strobe tube assembly while in operation. Wait 10
minutes after disconnecting the power source before starting any work on
the power supply or system.
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!
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. Refer to the mounting dimensions shown on the exploded product view.
Mark off and drill two 1/4” mounting holes for two #10 x 1-1/4 sheet metal
screws into the mounting surface.
2. Drill a 1” wire hole and deburr the hole.
3. Feed the 15’ lighthead cable (included) through the wire hole and route it
towards your control head. Pass the lighthead connector through the
mounting gasket and the wire hole grommet (included) before connecting
the lighthead to the lighthead cable.
4. Connect the lighthead to the cable and install the grommet into the wire
hole. Secure the lighthead to the mounting surface using the two mounting
screws supplied.
5. Finish the installation by securing the gasket, lens and lens retainer with the
two lens screws.
6. Use the wiring diagram for the model being installed to complete the
electrical connections.
Scan-Lock™: To advance pattern: With the lighthead active, apply
+VBAT to the WHT/VIO wire for less than 1 second. To cycle to previous
patterns: Apply +VBAT for more than 1 second. To restore factory
default pattern: Turn off power to the lighthead. Apply +VBAT to the
WHT/VIO wire while turning the lighthead on. Continue to apply voltage to
the WHT/VIO wire for 5 seconds.
Mounting
Surface
Remember, the grommet must
be installed over the lighthead
connector before the grommet
is mounted onto the wire hole.
Grommet
Mounting
Gasket
SYNC Operation (LED models only): Some of the patterns available for
the standard SYNC lighthead are described as being either Phase 1
(PH.1) or Phase 2 (PH.2), Phase 3 (PH.3) or Phase 4 (PH.4). These terms
define how patterns on lightheads with their SYNC wires connected relate
to each other. Lightheads configured to display the same Phase of a given
pattern will flash simultaneously. Lightheads configured to Phase 1 of a
given pattern will alternate with Phase 2 lightheads. This concept is more
easily understood using the following illustration:
Split Lighthead Operation
1. SignalAlert™ 75................ PH.1
2. SignalAlert 75 ................... PH.2
3. SignalAlert 75 ................... PH.3
4. SignalAlert 75 ................... PH.4
5. CometFlash® 75............... PH.1
6. CometFlash 75 ................. PH.2
7. CometFlash 75 ................. PH.3
8. CometFlash 75 ................. PH.4
9. DoubleFlash 75 ............... PH.1
10. DoubleFlash 75 ............... PH.2
11. DoubleFlash 75 ............... PH.3
12. DoubleFlash 75 ............... PH.4
13. SingleFlash 75................. PH.1
14. SingleFlash 75................. PH.2
15. SingleFlash 75................. PH.3
16. SingleFlash 75................. PH.4
17. ComAlert™ 75 .................. PH.1
18. ComAlert 75...................... PH.2
19. ComAlert 75...................... PH.3
20. ComAlert 75...................... PH.4
21. LongBurst™ 75 ................. PH.1
22. LongBurst 75 .................... PH.2
23. LongBurst 75 .................... PH.3
24. LongBurst 75 .................... PH.4
25. PingPong™ 75 ................ PH.1
26. PingPong 75 .................... PH.2
27. PingPong 75 .................... PH.3
28. PingPong 75 .................... PH.4
29. SSNF 75 ........................... PH.1
30. SSNF 75 ........................... PH.2
31. SingleFlash 60.................. ALT
32. SingleFlash 60...................SIM
33. SingleFlash 90.................. ALT
34. SingleFlash 90...................SIM
35. SingleFlash 120................ ALT
36. SingleFlash 120.................SIM
37. SingleFlash 300 ..................ALT
38. SingleFlash 300 ..................SIM
39. DoubleFlash 150.................ALT
40. DoubleFlash 150.................SIM
41. ComAlert150.......................ALT
42. ComAlert150.......................SIM
43. ActionFlash™50 .................ALT
44. ActionFlash50 .....................SIM
45. ActionFlash150 ...................ALT
46. ActionFlash150 ...................SIM
47. ModuFlash™ ......................ALT
48. ModuFlash ..........................SIM
49. DoubleFlash 120 .............. ALT
50. DoubleFlash 120 ...............SIM
51. PingPong™ 120 ............... ALT
52. PingPong 120 ....................SIM
53. TripleFlash™ 75 ............... ALT
54. TripleFlash 75....................SIM
55. TripleFlash 120................. ALT
56. TripleFlash 120..................SIM
57. SigAlert Cal.™.................. ALT
58. SigAlert Cal. ......................SIM
59. Action 1............................. ALT
60. Action 1..............................SIM
61. Action 2............................. ALT
62. Action 2..............................SIM
63. CalScan™ .................. ALT/SIM
64. ActionScan™ .............. ALT/SIM
65. SteadyFlash 60
66. SteadyFlash 75
67. SteadyFlash 90
68. SteadyFlash 120
69. Steady & Steady
NOTE: BOLD = California Title XIII Compliant Pattern Italic = SYNC Patterns
NOTE: PHASE 1 ALWAYS ALTERNATES WITH PHASE 2
PHASE 3 ALWAYS ALTERNATES WITH PHASE 4
NOTE: The SYNC wire can be connected to other SYNC-capable power
supplies to synchronize their output.
Be sure to cap the SYNC wire if it is not used.
IMPORTANT! Before returning the vehicle to active service, visually
confirm the proper operation of this product, as well as all vehicle
components/equipment.
Flash Patterns

Page 3
PART NUMBER KEY:
COLOR CABLE REQ.
01-0682082-__
COLOR: R -
B-
G-
A-
C-
RED
BLUE
GREEN
AMBER
CLEAR
COLOR:
COLOR:
COLOR:
COLOR:
CABLE: 0 - NO CABLE
1-with CABLECABLE:
LENS / RED
CABLE ASS'Y.
BASEPLATE GASKET
BASEPLATE
#10 x 1-1/4 PPH SMS
SCREW GROMMET
SCREW GROMMET / #242-180602-91-0101
REFLECTOR ASS'Y.
#6 x 5/8 PAN HD. THD. FORM SCREW
LENS GASKET
LENS GREEN/
LENS CLEAR/
LENS BLUE/
LENS AMBER/
LENS RETAINER
HELS™ LIGHTHEAD ASSEMBLY
68-4170581-50
02-0240624-15
38-0261715-00
06-182081-001
13-062C40-16J
21-17060704-3
02-0282121-00
38-0270590-01
68-4170581-40
68-4170581-30
68-4170581-20
68-4170581-10
19-190154-003
01-0682082- ( )
A/R
A/R
1
1
1
2
3
2
1
3
1
A/R
A/R
A/R
A/R
1
ITEM PART NUMBER DESCRIPTION
00-0000000-00
QTY
2
3
11
12
13
14
15
16
17
4
5
6
7
8
9
10
1
#10 x 5/8 PFH SMS
2
1” GROMMET
21-11263204-0
Mounting
Dimensions
Drill a 1” diameter wire hole
in this approximate location.
Mounting hole
#10 X 1-1/4 PPH SMS"
Mounting hole
#10 X 1-1/4 PPH SMS"
7.53"
4.31"1.45"
VOLTAGE
ANODE - TRIGGER -225 volts (Minimum) 150 volts (Minimum)
STROBE WIRING DIAGRAM
CABLE
WHITE - TRIGGER
BLACK - CATHODE
RED - ANODE
TO STROBE
POWER
SUPPLY
321
17
16
15
10 11 12 13
4
5
6
7
8
9
14
12 3

Page 4
PART NUMBER KEY:
LENS/COLOR CABLE
01-0684474-__
LENS/COLOR: A -
B-
G-
R-
AMBER
BLUE
GREEN
RED
1-
2-
3-
4-
5-
AMBER/CLEAR
BLUE/CLEAR
WHITE/CLEAR
GREEN/CLEAR
RED/CLEAR
CABLE: 0 - NO CABLE
1-with CABLECABLE:
#10 x 1-1/4 PPH SMS
CONN./CABLE ASSEMBLY (18 AWG)
1” GROMMET
BASEPLATE GASKET
BASEPLATE
AMP 4-POS. PIN HOUSING
MOUNTING BRACKET
SCREW GROMMET
#6 / #8 FASTEX GROMMET
REFLECTOR ASSEMBLY - AMBER
REFLECTOR ASSEMBLY - BLUE
REFLECTOR ASSEMBLY - CLEAR
REFLECTOR ASSEMBLY - GREEN
REFLECTOR ASSEMBLY - GREEN
HELS™ LED LIGHTHEAD ASSEMBLY
LENS / RED
LENS GASKET
LENS GREEN/
LENS CLEAR/
LENS BLUE/
LENS AMBER/
LENS RETAINER
#10-5/8 PFHSMS SCREW
#6-3/8 PPH PLASTI-LOK SCREW (BLK)
68-4170581-50
38-0270590-01
68-4170581-40
68-4170581-30
68-4170581-20
68-4170581-10
19-190154-003
15-06521B-060
46-0746533115
21-11263204-0
38-0261715-00
06-182081-001
39-0404313-04
07-264595-023
21-17060704-3
13-062C40-16J
01-0264605-10
01-0264605-20
01-0264605-30
01-0264605-40
01-0264605-50
01-0684474- ( )
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
1
1
2
2
3
3
2
1
1
1
1
1
1
ITEM PART NUMBER DESCRIPTION
QTY
2
3
11
12
13
14
15
16
17
18
19
20
21
22
23
4
5
6
7
8
9
10
1
Drill a 1” diameter wire hole
in this approximate location.
Mounting hole
#10 X 1-1/4 PPH SMS"
Mounting hole
#10 X 1-1/4 PPH SMS"
7.53"
4.31"1.45"
8
6
21
7
4
5
3
2
1
22
23
13
20
19
14 15
9
16
10
17
11
18
12
LED WIRING DIAGRAM
Momentary Switch*
(normally open)
SP/ST Switch* 3A Fuse*
*= customer supplied
WHT/VIO - Scan-Lock™ +12VDC
GRY - SYNC SYNC to desired Sync-capable Lighthead
BLK - Ground
LED Color -+12VDC
3421
(+)
Battery
(-)