Whelen Engineering Company AF-6016 User manual

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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.
• 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: Flashers
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.
©1993 Whelen Engineering Company Inc.
Form No.13672 (031102)
Installation Guide
Model AF-6016
Ambulance Halogen Flasher System
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.

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AMP 3 POSITION SOCKET HOUSING
AMP 3 POSITION PIN HOUSING
RED WIRE
RED WIRE,
POSITION 1
MOUNTING
SCREWS.
LEXAN®
OPTIC LENS.
REFLECTOR
WITH TWIST-IN
HALOGEN
BULB
ASSEMBLY.
WHITE WIRE,
POSITION 3
2 WIRE PIGTAIL ASSEMBLY, PART
NUMBER 46-0920802-00.
1 SUPPLIED WITH EACH HALOGEN
LIGHTHEAD ASSEMBLY.
WHITE WIRE
THE FLASHER CONTROL MODULE, MODEL AF-6016, IS
COMPLETELY FACTORY ASSEMBLED, WIRED AND TESTED,
READY FOR THE REMOTE HALOGEN LIGHT HEAD CABLES
TO BE CONNECTED.
(SEE IMPORTANT GROUNDING NOTE ON PAGE 3).
The 16 connectors mounted on the halogen flasher control
module, are AMP 3 position socket connectors. Each one of these
connectors is clearly numbered and labeled on the internal slide-
on cover (see figure 5, page 3), to indicate where the remote
halogen light head assemblies should be connected. The right
side and left side designation used for positioning of the light head
assemblies is based on the direction of travel of the vehicle.
INSTALLING THE HALOGEN LIGHTING SYSTEM.
To install the Model AF-6016 flasher control module and the
halogen lighting system on the vehicle, it is recommended
following the general order of steps as indicated below:
1. Choose an accessible location for the halogen flasher control
module, protected from the weather and abuse.
2. Determine, on the vehicle, the desired locations of the remote
halogen light head assemblies.
3. String interconnecting cables from halogen flasher control
module to the locations chosen to hold the remote halogen
light head assemblies.
4. Connect the interconnecting cables to the halogen flasher
control module. IMPORTANT NOTE: MAKE SURE THE
HALOGEN CONTROL FLASHER MODULE IS NOT
CONNECTED TO POWER SOURCE.
5. Install, at the chosen locations, the remote halogen light head
assemblies, and connect them to the interconnecting cables.
Do not, at this time, finalize the installation of the light heads
until the system's final test.
6. Install control switch and connect to halogen flasher module.
7. Install and connect the two input power cables to the power
source of the vehicle (battery), and test the halogen light
system.
NOTE: When passing interconnecting cables through metal
surfaces, remove burrs from edges of the holes, and, if possible,
use rubber grommets to protect the cables. It is advisable to
support the cables with cable ties, cable clamps, or with any other
means, to make sure the interconnecting cables will not shift
around or put tension on the connectors.
MOUNTING THE MODEL AF-6016 HALOGEN FLASHER
MODULE.
When choosing the location for installing the halogen flasher
module, the following guidelines should be considered:
• The unit must be mounted with the cooling fins in the
vertical plane for maximum heat dissipation (see figure
1). Because of the weight of the power wires, it is
recommended keeping the two power input studs (see
figure 5, page 3, and figure 7, page 4) on the bottom of
the halogen flasher module.
• Keep enough clearance, 3
inches minimum, around the
unit for proper ventilation,
and room for easy access to
the remote halogen light
head interconnecting cable
connectors. Sufficient room
is also required to remove or
install both the module outer
cover (figure 4), and the
internal slide-on cover
(figure 5).
• Mount the halogen flasher
module on a metal surface to
enhance heat dissipation.
INSTALLING HALOGEN LIGHT
HEAD INTERCONNECTING
CABLES (customer supplied).
IMPORTANT NOTE: DURING THIS OPERATION MAKE SURE
HALOGEN FLASHER MODULE IS NOT CONNECTED TO
POWER SOURCE.
1. The interconnecting cables should be a minimum size of 16
AWG, with color coded wires. The halogen flasher module
Model AF-6016 is supplied with sixteen 2 wire pigtail
assemblies (see figure 7, page 4), one for each of the
halogen connectors. Each one of these connectors is clearly
numbered and identified on the slide-on plate. Butt splice
these pigtail assemblies to the interconnecting cables and
insert in the proper halogen connector. A good installation
practice is to label the opposite end of the interconnecting
cable with an indelible marker with the number of the halogen
connector to which it is connected. Leave a service loop in
the interconnecting cable at the halogen flasher module
location, if ever maintenance should be required at a later
date.
2. Route the interconnecting cables through the vehicle to the
location chosen for installation of the remote halogen light
head assemblies (see figure 6, page 4). Cut interconnecting
cable length leaving an allowance for a service loop. During
the installation of the interconnecting cable avoid sharp
edges and chafe points.
3. Each Whelen halogen remote light head assembly is
supplied with a 2 wire pigtail assembly (see figure 2), to be
butt spliced to the interconnecting cables. Make sure, when
butt splicing, to match the colored wires of the pigtail
assembly to the same colored wires of the flasher module.
FIGURE 1.
FIGURE 2.

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#6 x ¼ INCH PHILLIPS PAN HEAD
SHEET METAL SCREWS
PLASTIC OUTER COVER
P/N 11B285469-000
MOUNTING TABS FOR
MOUNTING THE HALOGEN
FLASHER MODULE
MODE CONTROL
CONNECTOR
BLACK PVC SHIELDS
LOCATED INSIDE ON BOTH
THE POSITIVE AND NEGATIVE
TERMINAL SIDES
FIGURE 5.
REMOVING INTERNAL SLIDE-ON COVER.
FIGURE 3.
MODULE ENCLOSED.
FIGURE 4.
REMOVING OUTER COVER.
SLIDE-ON INNER COVER
P/N 11-266628-000
(FEATURES IMPORTANT
FUSE AND HALOGEN
CONNECTION INFORMATION)
HALOGEN
CONNECTORS
POWER INPUT STUDS
FUSES
HALOGEN FLASHER
ASSEMBLY HOUSED
IN ALUMINUM EXTRUDED
HOUSING
P/N 01-0267564-00
INSTALLING THE REMOTE HALOGEN LIGHT HEAD
ASSEMBLIES.
The head assemblies are supplied un-assembled, and parts
vary for the different models making up the system. After
connecting the halogen reflectors to the interconnecting
cables using the 2 wire pigtail assemblies (see figure 2, page
2), install the unit according to the instructions provided with
the halogen light heads. It is recommended not to finalize the
installation of the individual remote halogen light head
assemblies until the complete system has been tested, since
it is possible that minor adjustments may be needed later on.
CONNECTING THE HALOGEN FLASHER MODULE,
MODEL AF-6016, TO THE CONTROL SWITCH (customer
supplied).
The halogen flasher module is supplied with one 2 wire pigtail
assembly to be connected to customer supplied mode control
switch (see figure 7, page 4). The control switch, to be
installed inside the vehicle's cab, is of the single pole, double
throw, center off type. In the Mode 1 position (primary mode),
all remote halogen light head assemblies on the vehicle are
flashing. In the Mode 2 position (secondary mode), only the
remote halogen light head assemblies, located on the box of
the vehicle, will be flashing. The flashing sequence of both
modes is controlled by the halogen flasher module. ùNOTE:ú
Control switch will be wired directly to the positive post on the
power source (see figure 7, page 4).
CONNECTING THE HALOGEN FLASHER MODULE,
MODEL AF-6016, TO THE POWER SOURCE (battery).
IMPORTANT NOTE: DURING THIS STEP, MAKE SURE
THAT CONTROL SWITCH IS IN THE OFF POSITION.
Use two #8 AWG minimum size wires (customer supplied)
with ring lugs to fit the power input studs located on the
halogen flasher unit (see figure 7, page 4). These studs are
clearly marked positive (+) and negative, and are colored red
and black respectively. Connect the positive wire (+) directly
to the battery positive post through a customer supplied 50
amp master fuse (see figure 7, page 4). Install this master
fuse as close to power source as possible. Connect the
negative wire (-) directly to the battery negative post.
IMPORTANT GROUNDING NOTE: The halogen flashing system described in this manual is a 2 wire system. DO
NOT ground any of the connections making up this system, located either on the flasher control module, or the
remote halogen light assemblies. If remote halogen light head assemblies, other than Whelen made, are used in
the system, makesure that none of the connections are grounded. The only grounded connection in the system
should be the negative wire running from the flasher control module to the power source. System will not function if
grounding is done in any way other than indicated above.

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RED
RED
RED
RED
RED
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9
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7
6
5
4
3
2
1
RED
RED
RED
RED RED
RED
RED AMBER
CLEAR
HALOGEN FLASHER CONTROL
MODULE CONNECTOR POSITIONS.
FOR RECOMMENDED CABLING
INSTRUCTIONS SEE PAGE 1.
COLOR CODED INTERCONNECTING CABLES (CUSTOMER SUPPLIED) TO
BE USED TO CONNECT REMOTE LIGHT HEAD ASSEMBLIES TO HALOGEN
FLASHER CONTROL MODULE, MUST BE A MINIMUM OF 16 AWG.
TEN MAX HALO-BEAM®HALOGEN REMOTE
LIGHT HEAD ASSEMBLIES AROUND BOX.
TWO INTERSECTOR™ HALOGEN LIGHT
HEAD ASSEMBLIES, ONE ON EACH SIDE.
TWO GRILL MOUNT
REMOTE HALOGEN
LIGHT HEAD
ASSEMBLIES, ONE
ON EACH SIDE
FIGURE 6.
DIAGRAM OF HALOGEN LIGHTING SYSTEM, AAMVA
CERTIFIED, WITH USE OF WHELEN REMOTE
LIGHTHEAD ASSEMBLIES, AND MODEL
AF-6016 HALOGEN
FLASHER MODULE.
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3
1
2
3
4
5
6
7
8
3
HALOGEN LIGHT CONNECTOR 2 WIRE PIGTAIL ASSEMBLY.
PART NUMBER: 46-0721538-00. 16 SUPPLIED, ONE FOR EACH OUTLET.
RED WIRE, TO POSITIVE (+) CONNECTION OF HALOGEN LIGHT HEAD.
WIRE TO POWER SOURCE POSITIVE, CUSTOMER SUPPLIED.
MODE CONTROL 2 WIRE PIGTAIL ASSEMBLY,
P/N 02-0241094-00 (SUPPLIED).
3 POSITION AMP PIN CONNECTOR.
3 POSITION AMP SOCKET CONNECTOR.
MODE 1,
PRIMARY
OFF
MODE 2,
SECONDARY
1 AMP FUSE
CUSTOMER
SUPPLIED.
SINGLE POLE, DOUBLE THROW,
CENTER OFF CONTROL SWITCH,
CUSTOMER SUPPLIED AND WIRED. BLACK WIRE
WHITE WIRE
3 AMP FUSE PROTECTING MODE
CONTROL CONNECTION.
AMP THREE POSITION
PIN CONNECTOR FOR
MODE CONTROL.
AMP 3 POSITION SOCKET
CONNECTORS FOR
REMOTE HALOGEN LIGHT
HEAD ASSEMBLIES (SEE
FIGURE 6 ABOVE).
CONNECTORS NUMBER
15 AND 16 ARE
AVAILABLE AS AUXILIARY
OUTLETS.
NOTE: OUTLET 16 IS OFF
IN MODE 2
CUSTOMER SUPPLIED
POWER WIRE,
#8 AWG. MINIMUM,
TO BE CONNECTED
DIRECTLY TO
BATTERY POSITIVE (+).
CUSTOMER SUPPLIED
GROUND WIRE,
#8 AWG. MINIMUM,
TO BE CONNECTED
DIRECTLY TO
BATTERY GROUND (-).
MASTER
50 AMP FUSE
OR CIRCUIT
BREAKER,
CUSTOMER
SUPPLIED.
AMP 3 POSITION SOCKET CONNECTORS
FOR REMOTE HALOGEN LIGHT HEAD
ASSEMBLIES (SEE FIGURE 6 ABOVE).
POWER INPUT STUD,
NEGATIVE (-).
7.5 AMP FUSES, PROTECTING EACH HALOGEN CONNECTION
WHITE WIRE, TO RETURN (-) CONNECTION OF HALOGEN LIGHT HEAD (DO NOT GROUND ANY CONNECTION OF LIGHT HEAD).
FIGURE 7.
TOP VIEW OF HALOGEN FLASHER CONTROL MODULE WITH INTERNAL SLIDE-ON COVER REMOVED (see figure 5, page 2).
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