Whelen Engineering Company 1200D Series User manual

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©1997 Whelen Engineering Company Inc.
Form No.13208E (121506)
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:
Strobe Beacon Assembly
1200D-series
®
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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The 1200D Series Strobe Beacon features a combination
base which may be used for either 1” (NPT) Pipe Mount, or
Permanent Mount. The threading for a 1 inch (NPT) pipe
mounting is precast in the die-cast base. Magnetic Mount and
Spade Mount models are also available.
FEATURES:
• Input Voltage: 12VDC and 24VDC
• Input Current: 2.5A @12.8V and 1.5A @25.6V
• Output Power: 25 Watts
• 4 Selectable Flash Patterns
• Selectable Manual Hi/Lo Intensity Mode
• Automatic Photocell Hi/Lo Intensity Mode (Optional).
• Permanent / Pipe Mounting Standard.
• Spade Bolt and Magnetic Mounting (Optional).
• High / Off / Low Intensity Switch (Optional).
• 4 Pattern Beacon Controller with Diagnostic &
Manual
• Hi/Lo Intensity Control (Optional).
• Factory Installed Cruise Light (Optional).
Installation: Permanent Mount
1. Using the base gasket as a template, mark the 2
mounting holes and the center wire access hole onto the
mounting surface (Fig. 3).
2. First drill holes for the two 10 X 5/8” pan head sheet
metal screws (supplied in parts bag). IMPORTANT: Be
very careful not to drill the holes too large.
3. Next drill the wire access hole with a 1/2” drill. NOTE:
You should also install a rubber grommet in the wire
access hole to protect the wires.
4. Place base gasket on mounting surface aligned with the
holes in the mounting surface. After connecting the
strobe beacon to the power cable, feed the wires through
the wire access hole. Place strobe beacon into proper
position, align the 2 holes in the aluminum base with the
2 mounting holes in the base gasket and mounting
surface. Use the 2 enclosed sheet metal screws to
attach the strobe light beacon securely to the mounting
surface.
Installation: Pipe Mount
1. Feed power cable through the 1 inch pipe. Connect the
cable to the wires of the 1200D Series strobe beacon.
2. Screw the strobe beacon into the threads on the 1 inch
pipe, taking precaution not to damage the connected wires.
Installation: Spade Bolt Mount
This mounting of the 1200D Series strobe beacon is a tamper
proof way to secure the unit to the mounting surface. If you
want this feature, you must have the “Spade Bolt Mount” model.
This model will have the bolts already installed into the
aluminum base. The mounting screws are hidden inside the
base, and are not accessible unless the strobe beacon is
disassembled.
1. Using the base gasket as a template, mark the 3 mounting
holes and the center wire access hole onto the mounting
surface. IMPORTANT: You must have access to the other
side of the mounting area to attach the nuts to the
mounting bolts.
2. Drill the three holes for the mounting bolts.
3. Next drill the wire access hole with a 1/2” drill. Install a
rubber grommet in the wire access hole to protect the
wires.
4. Put your gasket in place on the mounting surface, run the
wires through the mounting hole and connect the beacon
to your power source.
5. Now take your beacon and slip the 3 bolt ends (coming
from the aluminum base) into the 3 mounting holes.
6. Attach and tighten the 3 nuts (Fig. 4) and your beacon is
ready.
WARNING: The use of any magnetically mounted warning
beacon on the outside of a vehicle while in motion is not
recommended and is at the sole discretion and risk of the
user
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!
WARNING: The aluminum base has a small drain hole on
the side, located toward the bottom. This hole must be
positioned so that it faces the rear of the vehicle for proper
drainage.
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.

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(CUSTOMER SUPPLIED)
(24VDC - 3 AMP FUSE)
12VDC - 5 AMP FUSE
WIRING DIAGRAM
LED DIAG.
GRN
WHT
BRN
VIO
PATTERN 2
PATTERN 1
HI/LO CTRL
BATTERY
GNDBLK
RED
ON/OFF
CRUISE
GRY
BROWN
WHITE
RED
BLACK
BASE
SCREW
(QTY. 2)
DIE-CAST
BASE
OPTIC
DOME
DIE-CAST
BASE
SCREWS
(QTY. 2)
GASKET
POLISHED
ALUMINUM
BASE
10 X 5/8
PAN HEAD
SHEET METAL
SCREW(QTY.2)
(PERM. MOUNT)
10-24
WHIZ
NUT
(QTY. 3)
MOUNTING
BOLTS
(QTY. 3)
(SPADE
MOUNT)
3
12
2
13INPUT
CONTROL
PIGTAIL
ASSEMBLY
GRAY / OPTIONAL
W/ CRUISE LIGHT
GREEN / OPTIONAL
W/ DIAGNOSTICS
SOCKET
PIN
WIRE ACCESS
HOLE (1/2")
3.25
6.50
PERMANENT
MOUNT
MOUNTING HOLES
Fig. 1
®
JU1
JU2 JUMPERS
Fig. 2
Fig. 3
Fig. 4

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CUT VIOLET
WIRE HERE
PLUG WIRE HERE
ATTACH SOCKET HERE
AND INSERT INTO
SOCKET HOUSING
RED
BLACK
VIOLET
RUN THROUGH
BASE HERE
3
12
2
13
CUSTOMER OPTIONS
Hi/Lo Intensity Option:
1. Take out the 2 base screws and remove the optic dome
(Fig. 4).
2. Locate and remove the 2 screws holding the die-cast base
to the aluminum base.
3. Separate the aluminum base and die-cast base so you
have access to the wiring as shown in Fig. 4 (you will see
that the violet and black wires run together).
4. Cut the violet wire as indicated in Fig. 5 (at pin 2). Attach
the supplied socket to the end of the violet wire and insert
it into the number 3 space in the socket. NOTE: Cut the
wire close to the socket, so it doesn’t stick out.
5. Next take the violet wire with the pin attached (included in
the installation kit) and plug it into the connector as shown
in Figure 5.
6. Run the wires out the bottom of the aluminum base and
reassemble the beacon.
7. Now, if you ground the violet wire, your light will run at high
intensity, and if you tape off the violet wire, your light will
run at low intensity. You may want to install a two position
switch so you can alternate between the two functions
(see wiring options in Fig. 6).
Flash Pattern Options:
The default flash pattern for the 1200D is Comet Flash. You
may choose from several other patterns by making a few simple
changes.
1. First remove the optic dome by removing the 2, die-cast
base screws (Fig. 4).
2. Remove the 2 screws holding the die-cast base to the
aluminum base and separate them, exposing the wires.
3. Find the input control pigtail assembly in your parts bag,
and plug it in to the extra connector coming out of the die-
cast base.
4. Run the brown and white wires out through the center of
the base as shown in Figure 4. IMPORTANT: Be sure to
tape off any unused wires.
5. Reassemble the unit and you are ready to choose your
options.
To Select Single Flash: Ground the white wire and tape off the
brown wire.
To Select Double Flash: Ground the brown wire and tape off
the white wire.
To Select Action Flash: Ground both the white and brown
wires.
Jumper Options:
There are several options you can utilize by cutting one, both or
neither of the jumpers located inside the unit (the jumpers are
labeled JU1 and JU2. see Fig. 3).
A. You may run your strobe at either high or low intensity. To
accomplish this you simply leave both jumpers intact and
follow the instructions under “Hi/Lo Intensity Option”.
B. Your strobe may also be equiped with the optional
“Photocell function”. This will automatically adjust the
intensity of the strobe light acording to the ambient light
(darkness switches the beacon to low power, while daylight
switches the beacon to high power). To engage this
function you must cut the JU2 jumper and leave the JU1
jumper intact. Then clip the violet wire and tape it off (see
“Hi/Lo Intensity Option”). Now the photocell option is
always engaged. If you want to be able to turn this function
on or off manually, you must also attach the violet wire to a
switch that will ground or disconnect it. When you switch to
“ground” the light will always be at high intensity. When you
switch to “disconnect” the light will return to the photocell
function.
C. If you want your strobe to turn on automatically during the
day and off at night, cut the JU1 jumper and leave JU2
jumper intact.
D. If you want your strobe to turn off automatically during the
day and on at night, cut both the JU1 and JU2 jumpers.
IMPORTANT NOTE: Both “C” and “D” are usually used for
remote applications. Once you convert to either of these
functions you will not be able use the light any other way.
Fig. 5

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BLACK WIRE, NEGATIVE (-)
RED WIRE, POSITIVE (+)
ON/OFF SWITCHFUSE
WIRES TO POWER SOURCE WIRES TO STROBE
LIGHT HEAD ASSEMBLY
DOUBLE POLE, DOUBLE THROW
CENTER OFF SWITCH (REAR VIEW)
BLACK WIRE, NEGATIVE (-)
RED WIRE, POSITIVE (+)
RED WIRE, POSITIVE (+)
BLACK WIRE, NEGATIVE (-)
VIOLET WIRE, NEGATIVE (-) HI/LOW
WIRES TO POWER SOURCE WIRES TO STROBE
LIGHT HEAD ASSEMBLY
FUSE
GRAY WIRE, POSITIVE (+) CRUISE LIGHT, 12 OR 24 VDC
DOUBLE POLE, DOUBLE THROW
CENTER OFF SWITCH (REAR VIEW)
BLACK WIRE, NEG. (-)
RED WIRE, POS. (+)
RED WIRE, POSITIVE (+)
BLACK WIRE, NEGATIVE (-)
VIOLET WIRE, NEGATIVE (-) HI/LOW
WIRES TO POWER SOURCE WIRES TO STROBE
LIGHT HEAD ASSEMBLY
FUSE
GRAY WIRE, POSITIVE (+) CRUISE LIGHT, 12 OR 24 VDC
1 AMP FUSE
MODEL 1200D STANDARD.
ON/OFF SWITCHING
FOR HIGH POWER
ONLY.
MODEL 1200D STANDARD.
HIGH-OFF-LOW SWITCHING.
NOTE: Cut Violet (looped) wire, run
itoutofunitwithblackandredwires.
When the violet wire is grounded,
you are in the high mode and
when the violet wire is floating
you are in the low mode.
IMPORTANT: Cruise light
is12VDCor24VDCbulb.
MODEL 1200D WITH CRUISE
LIGHT OPTION.
NOTE: Strobe light and cruise light
are connected to same DPDT
CENTER OFF switch control.
MODEL 1200D WITH CRUISE
LIGHT OPTION.
IMPORTANT: Cruise light
is12VDCor24VDCbulb.
NOTE: Strobe light is controlled by
DPDT CENTER OFF switch control,
and cruise light is controlled by
ON/OFF switch control.
NOTES: 5 AMP
3 AMP 24 VDC
ALL SWITCHES AND FUSES ARE CUSTOMER SUPPLIED. USE FUSE FOR 12 VDC
OPERATION, AND FUSE FOR OPERATION.
SWITCH CONTROL WIRING SCHEMATICS FOR THE 1200D STROBE LIGHT SERIES
+
+
BLACK WIRE, NEGATIVE (-)
RED WIRE, POSITIVE (+)
RED WIRE, POSITIVE (+)
BLACK WIRE, NEGATIVE (-)
VIOLET WIRE, NEGATIVE (-) HI/LOW
WIRES TO POWER SOURCE WIRES TO STROBE
LIGHT HEAD ASSEMBLY
FUSE
DOUBLE POLE, DOUBLE THROW
CENTER OFF SWITCH (REAR VIEW)
+
+
Fig. 6