Whelen Engineering Company NITEBEAM H.I.D. Installation instructions manual

1
©1998 Whelen Engineering Company Inc.
Form No. 13335B (091099)
MOUNTING GUIDE FOR THE
NITEBEAM H.I.D. FLOODLIGHT
®
ENGINEERING COMPANY INC.
For warranty information regarding this product, visit www.whelen.com/warranty
Automotive: Lightheads
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Customer Service e-mail: [email protected]
INSTALLATION:
The Nitebeam Floodlight carries a high intensity discharge
lamp. Therefore it is essential that the operator pay close
attention to all warnings and cautions listed in this manual.
PERMANENT MOUNTING:
When selecting the mounting location for the Nitebeam, be
sure to check that no vehicle components will interfere with
the mounting location of this unit. Position the Nitebeam on
the proposed mounting location. Using the bail strap as a
template, scribe the mounting surface with an awl or other
suitable tool to indicate where the mounting holes are to be
drilled. (Figure 2, Mounting Dimensions)
CAUTION: As the installation of the Nitebeam will require
drilling, it is absolutely necessary to make sure that no
other vehicle components could be damaged in the
process. Check both sides of the mounting surface before
drilling and if damage is possible, select a different
mounting location.
Carefully drill the mounting holes in the areas scribed. The
diameter of these holes will be determined by the size of
the mounting hardware and the thickness of the mounting
surface. Secure the unit with customer provided sheet
metal screws. (Ref. Figure 1)
PORTABLE MOUNTING / OPTIONAL
Secure the suction cup to the Nitebeam bail strap using
the metric nut provided with the kit. When selecting the
mounting location, be sure to look for a flat, smooth
surface. Place the Nitebeam on the proposed mounting
location with the suction cup firmly in place on the
mounting surface. Insert the suction engagement handle
into the suction cup as noted in Figure 1A, and push down
on the handle to secure the unit to the vehicle.
WIRING / OPTION
The Nitebeam is wired to a cigar plug where the grooved
wire is (+) positive and the smooth wire is (-) negative. If
the user chooses to wire this unit permanently into a
vehicle . . .
NOTE: 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. (Refer to the Electrical
Specification box on page 2.)
WARNING: The use of any suction cup mounted units on a
vehicle while it is in motion is at the sole discretion and risk of the
user. The suction engagement handle is a loosely shipped item.
Be sure not to lose this item.
WARNING:The outer surfaces of this product may be cleaned
with mild soap and water. Use of any other chemicals may void
product warranty. Do not use a pressure washer.
BAIL STRAP
3/8 - 16 x 1 -3/4 HEX
HEAD BOLT SS (QTY. 2)
MOUNTING SURFACE
POWER CABLE
PERMANENT MOUNT
SUCTION CUP
MOUNT
ENGAGEMENT
HANDLE
Optional
Fig. 1
Fig. 1A

2
MOUNTING DIMENSIONS
LEFT 3/8 SCREW
.375 DIAHOLE
9.53mm DIA
#10-24 THREAD
(TYP)
1.575 DIAB.C.
40mm DIA
5.90
148.86mm
.312DIAHOLE
7.92mm DIA
(2) PLACES
SPRINGW
ASHER
WARNING ABOUT THE NITEBEAM LAMP:
The 70 Watt Metal Halide Bulbs have an average life
rating of 10,000 hours. The Nitebeam reaches its maxi-
mum “burn level” or brightest beam level when set to a
±45 degree angle. The metal halide arc-tubes operate at
high pressure (up to 50 p.s.i.) and at very high tempera-
tures. Due to the nature of its attributes, the halide arc-
tube can unexpectedly rupture because of internal or
external factors such as a ballast failure or misapplica-
tion. An arc-tube rupture can result in the discharge of
extremely hot quartz particles (as high as 1832° F, 1000°
C). In the event of such a rupture there is a risk of per-
sonal injury, property damage, burns and fire. Therefore,
unless the bulb is being replaced, it should remain within
the housing and behind the protective
ultraviolet lens.
SAFETY FIRST:
Do not tamper with the safety features installed in the
Nitebeam. This lamp can cause serious skin burn and
eye inflammation from shortwave ultraviolet radiation. It
MUST be operated in an enclosed fixture which filters out
the radiation. The Nitebeam is provided with a “dead-
man’s” switch that prevents the bulb from functioning
unless the protective lens is in place. If the protective
ultraviolet lens cover is removed, the power will be termi-
nated automatically.
BULB REPLACEMENT:
When replacing the bulb do not remove or insert lamp
while the power is on. In order to prevent electrical shock
and burn hazards, allow the lamp to cool for at least five
minutes before removing. Do not remove lamp from
package until ready for use and then handle only with
clean cotton gloves. The oil from fingerprints causes hot
spots on the lamp that may cause whitish spotting and
premature lamp failure. If lamp is handled, fingerprints,
grease or oils may be removed from the bulb by washing
with alcohol. Dry lamp carefully with cotton or clean cloth.
OPERATION NOTES:
Proper care and maintenance will reduce the possibility
of an arc-tube rupture and premature lamp failure:
• Operate only with the Nitebeam unit to prevent
ballast failure.
• Turn lamp off at least once a week for a minimum of
fifteen minutes.
• Do not expose operating lamp to moisture.
• Replace lamp if bulb is scratched, cracked or
damaged in any way.
IMPORTANT!!
FIGURE 2.
REPLACEMENT PARTS LIST
Suction Cup Mount (Kit) ................. 01-0416591-00
H.I.D. 70 Watt Lamp ....................... 34-1816623-4E
3/8-16 x 1-3/4 Hex Head Bolt SS ... 14-156436-280
3/8 Split Lock Washer SS ............... 16-1532220-10
BaIl Strap Bracket ........................... 07-262718-010
3/8 Wave Washer ........................... 16-1552420-20
Lens Seal ........................................ 38-0142464-00
Glass Lens ...................................... 68-3642464-00
#10-24 x 3/4 PPHMS SS ................ 14-104216-120
ELECTRCAL
SPECIFICATIONS
THE 12 VDC VERSION:
Input Voltage --------- 12 VDC ±20%
Current Draw ---- 7 AMP @ 12 VDC
Power Output ---------------- 70 Watts
Voltage Trip Low -------- 9 VDC ±5%
Voltage Trip High ------ 18 VDC ±5%
THE 24 VDC VERSION:
Input Voltage --------- 24 VDC ±20%
Current Draw - 3.5 AMP @ 24 VDC
Power Output ---------------- 70 watts
Voltage Trip Low ------ 18 VDC ±5%
Voltage Trip High ------ 32 VDC ±5%
FEATURE: To enable
floodlight unit to ratchet
freely, loosen the left 3/8”
screw until resistance is
applicable for rotation.
(See Figure 2)