Whelen Engineering Company 2022 Series User manual

Page 1
©1999 Whelen Engineering Company Inc.
Form No.13439C (121906)
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:
2022-series Strobe Beacon
(Aluminum Base)
®
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

Page 2
14
20
24
11
918
21 14
6
23
WARNING: The strobe power supply is a high voltage device.
Do not remove strobe tubes or dismantle strobe light head
assembly while in operation. Wait 10 minutes after turning off
power before starting work or trouble shooting.
IMPORTANT: 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.
INPUT VOLTAGE
12.8V & 25.6V NOM.
2.5A & 1.25A AVERAGE
31.5 WATTS (TYP)
72 CFPM @ 100mS
115 DFPM @ 170mS
150-370-150 SFPM @ 3S
(1) COMET & (4) SINGLE
8.6/2.5/2.5/2.5/2.5 JOULES
22 WATTS (TYP)
INPUT CURRENT
INPUT POWER
FLASHRATE:
QUINT FLASH
DOUBLE FLASH
RAPID RANDOM
ACTION FLASH
ENERGY
OUTPUT POWER
SPECIFICATIONS:
CRIMP WIRES TO CUSTOMER SUPPLIED 2 CONDUCTOR CABLE. RED / POSITIVE
DC VOLTAGE. BLACK / NEGATIVE GROUND. CUSTOMER SUPPLIED SINGLE
THROW (SPST) SWITCH MAY BE USED TO CONTROL ON-OFF FUNCTION.
WHEN INSERTING FLASH TUBE
ASSEMBLY INTO STROBE POWER
SUPPLY ASSEMBLY, ALIGN THE
3 PRONGS ON THE FLASH TUBE
ASSEMBLY WITH THE SLOTS
ON THE STROBE POWER
SUPPLY ASSEMBLY.
IMPORTANT: SEE PAGE 3
FOR ASSEMBLY
INSTRUCTIONS.
13
3
12
10
1
15
7
8
9
2
PERFORATED CIRCLE IN BASE GASKET. REMOVE OUTER
PART TO FIT DIAMETER OF ALUMINUM BASE FOR PERM. MTG.
18
20
17
14
4
5
IMPORTANT: 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.

Page 3
QTY
1
QTY
1
ITEM
1
PART NUMBER
01-0683164LAP
02-0168490-00
01-0683164HAP
01-0683164HAR
01-0683165-00
DESCRIPTION
FINAL ASSEMBLY, MODEL 2022LC / VP422LC
PCB ASSEMBLY, MODEL 2022D SERIES / EXCEPT 2022AC
FINAL ASSEMBLY, MODEL 2022HC / VP422HC
FINAL ASSEMBLY, MODEL 2022RC
FINAL ASSEMBLY, MODEL 2022AC
1
1
QTY
1
1
1
1
QTY
-
1
1
1
1
1
1
1
1
2
1
3
2
2
1
1
1
1
1
1
1
1
2
1
3
2
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
06-180842-002
36-0341567-00
38-0441331-00
38-0240821-00
21-11091202-0
56-000000-100
23-0320760-00
13-062C40-16J
21-17020602-3
15-066939-056
15-041416-080
15-065419-080
21-12081205
06-146115-000
BASE, DIE CAST, BLACK W/1" NPT
FLASH TUBE ASSY / FTU 20W
"O" RING
SEAL, BASE
3/8 GROMMET P/N 901132093
TO-3P CHO THERM INSULATOR
SPRING CLIP, TRANSISTOR MOUNT
NUT, NO.6 FASTEX SCREW GROMMET
NUT #4 FASTEX SCREW GROMMET, NYLON
6-32 X 5/16 HEX WASHER HD THD FORMING
N0.4 X 1/2 PHILLIPS PAN HEAD SHEET METAL SCREW
6-32 X 1/2 PAN HD THD FORMING
SCREW GROMMET
MODEL 2022RC / BASE
1
1
1
1
1
1
4
1
3
2
2
1
-
1
1
1
1
1
2
1
3
2
2
1
--
-
1
-
1
1
3
1
3
17
18
21
22
23
24
11-760897-000
15-101416-100
11-481496-002
21-22081204-0
38-0241540-00
15-081416-080
MOUNTING COLLAR, BLACK
N0.10 X 5/8 PHSMS
MODEL 1200 SANDBLASTED BASE
HEYCO PLASTIC HOLE BUSHING
GASKET, MODEL 1200 BASE
N0.8 X 1/2" PPHSMS
2
1
1
1
2
3
-
-
-
---
--
--
--
1-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
OPTIC DOME / GREEN / LOW PROFILE / 4-3/4“
OPTIC DOME / AMBER / LOW PROFILE / 4-3/4“
OPTIC DOME / BLUE / LOW PROFILE / 4-3/4“
OPTIC DOME / AMBER / HIGH PROFILE / 5-3/4“
OPTIC DOME / GREEN / HIGH PROFILE / 5-3/4“
OPTIC DOME / RED / LOW PROFILE / 4-3/4“
OPTIC DOME / RED / HIGH PROFILE / 5-3/4“
OPTIC DOME / BLUE / HIGH PROFILE / 5-3/4“
OPTIC DOME / CLEAR / HIGH PROFILE / 5-3/4“
OPTIC DOME / CLEAR / LOW PROFILE / 4-3/4“
68-2180452-10
68-2180452-40
68-2180452-20
68-2180483-10
68-2180483-40
68-2180452-50
68-2180483-50
68-2180483-20
68-2180483-30
68-2180452-30
20
20
20
20
20
20
20
20
20
20
--
--
--
--
--
-
-
-
-
-
-
-
-
-
--102-0168499-00 PCB ASSEMBLY MODEL 2022AC ONLY -1
-
---
OPTIC DOME / VIOLET / LOW PROFILE / 4-3/4“
OPTIC DOME / VIOLET / HIGH PROFILE / 5-3/4“
68-2180452-VO
68-2180483-VO
20
20
--
-
-
01-0683165___
DOME
COLOR
BASE
PART
NUMBER
KEY
1
DOME:
COLOR:
BASE:
H=HIGHDOME L= LOW DOME
A= AMBER BC
GRV
= BLUE = CLEAR
= GREEN = RED = VIOLET
P= PERM MOUNT M= MAG MOUNT
NOTE: DC voltage models are polarity sensitive. If the positive and negative wires
are reversed the unit will not function. The fuse is installed between the power
source and the strobe light beacon IN THE POSITIVE (+) LINE (red wire) and must
be fused at the battery.
MOUNTING INSTRUCTIONS:
This strobe beacon features a combination base which may be used for either
FLANGE MOUNT, 1 INCH (NPT) PIPE MOUNT, or PERMANENT MOUNT. The
threading for a 1 inch (NPT) pipe mounting is precast in the cast aluminum base,
PCB ASSEMBLY (COMPONENT SIDE)
to dismantle strobe.Refer to diagram on page 1
JU1
BLACK
JU2
QUINT FLASH
DOUBLE FLASH
RAPID RANDOM
ACTION FLASH
JU1 JU2
IN
IN
CUT
CUT
IN
CUT
IN
CUT
FLASH PATTERN
HI/LOW PATTERN
If you wish to control High or Low Power
externally cut the Violet wire off at this point
and exit with black and red wires. If you
ground this wire you will go to high power.
You will probably want to install a switch
so you can switch to high or low.
JUMPER OPTIONS
To achieve any one of the 4 flash patterns
listed in the above chart, you must either
cut-out or leave-in one, two, both or neither
of the two jumpers.
If you do not touch the
jumpers the unit will default to "QuintFlash".
RED
JU6
DIMPLES
DIMPLES
TOP VIEW INSIDE BASE
SEE PG. 3
IMPORTANT
INFORMATION
ON BASE.
FLANGE MOUNT
1. Select the mounting location taking into consideration visibility of
the strobe light flash, mounting surface and ease of wiring.
2. Using the base gasket (ITEM 5) as a template, mark the 3 mount-
ing holes and center wire access hole onto mounting surface.
3. Drill three mounting holes using a #29 drill (.136 inch, 3.5mm).
4. Drill the wire access hole using a 3/8 inch drill (.375 inch,
9.5mm). Be sure to remove burrs from access hole to prevent
any damage to wires.
5. Place gasket (ITEM 5) on mounting surface aligned with the
holes in the mounting surface. After connecting the beacon to the
power cable, feed wires through wire access hole. Place beacon
into proper position and slip mounting collar (ITEM 17) over
beacon to fit around the base of the unit. Align the 3 holes in the
mounting collar with the 3 mounting holes in the mounting
surface. Use the 3 enclosed mounting screws (ITEM 18) to
secure beacon to mounting surface.
1 INCH (NPT) PIPE MOUNT.
1. Feed the power cable through the 1 inch pipe and connect the
cable to the wires of the beacon.
2. Screw the beacon to the threads on the 1 inch pipe, taking
precaution not to damage the connected power supply wires.
PERMANENT MOUNT
This mounting of the strobe beacon is a tamper-proof way to secure
the unit to the mounting surface. Mounting screws are hidden inside
the base, and aren’t accessible unless unit is dismantled.
1. Remove the screws holding on the optic dome (ITEM 20) and
remove the dome. Then remove the screws holding on the power
supply (ITEM 1) and remove the power supply.
2. Locate all four of the 0.164 inch dimples within the perimeter of
the cast aluminum base. (See illustration below). Punch these
dimples out to create a hole for the mounting screws to fit
through.
3. Using the base as a template mark the 4 mounting holes onto the
mounting surface. Remove the base and mark in the center of
the 4 mounting holes, the location of the wire access hole.
4. Drill the mounting holes into the mounting surface to fit customer
supplied mounting hardware, drill the wire access hole using a
3/8 inch drill (.375 inch, 9.5mm). Remove burrs from wire access
hole to prevent damage to wires. It is also recomended that you
install a rubber grommet in each wire hole to protect the wires.
5. The gasket (ITEM 5) will be used between the base and the
mounting surface. Cut the gasket along the perforated circle to fit
diameter of base.
6. After connecting beacon to power cable, feed the wires through
the cable access hole and place the base with the gasket on the
mounting surface, lining up the mounting holes in the base with
the ones in the mounting surface. Secure base firmly to mounting
surface with customers hardware and reassemble beacon.

Page 4
POWER SUPPLY ASSEMBLY
MOUNTING HOLES TRANSISTOR
MOUNTING
STUDS
TRANSISTOR
MOUNTING BOSS
TRANSISTOR
SPRING CLIP
CHO-THERM
INSULATOR
ASSEMBLY INSTRUCTIONS OF STROBE LIGHT
POWER SUPPLY ASSEMBLY TO CAST ALUMINUM
BASE, TO PREVENT ELECTRICAL SHORT CIRCUIT
BETWEEN THESE TWO PARTS
WARNING:
FIGURE 1.
FIGURE 2.
FIGURE 3.
The strobe light power supply is a high voltage device.
Do not touch or remove strobe tube assembly while unit is in operation.
Wait at least 10 minutes after turning off power before starting work or
any trouble shooting on the unit. On this page is described the assembly
procedure of the strobe light power supply to the cast aluminum base.
It is extremely important that the assembly steps, as described below,
be followed exactly, to insure the proper insulation of the strobe light
power supply from the cast aluminum base.
Lower the power supply assembly onto the cast aluminum
base, with the three mounting holes lined up with the holes located on
the three mounting studs of the cast aluminum base. During this ass-
embly operation, the transistor on the power supply assembly has to be
positioned on the outside of the transistor mounting boss. Secure the
strobe light power supply assembly to the mounting studs with enclosed
self tapping screws.
Slightly bend the transistor on the power supply away from
the transistor mounting boss. Slip the Cho-Therm insulator behind the
transistor with the hole directed towards the top (see figure 4 “A”).
Position the top of the Cho-Therm insulator against the circuit board
of the power supply assembly, making sure that some of it shows below
the transistor (See figure 4 “B”). It is important that the transistor on the
power supply assembly does not contact the transistor mounting boss at
any place, as to prevent a damaging electrical short circuit between the
strobe light power supply and the cast aluminum base.
Use the transistor spring clip to secure firmly the Cho-Therm
insulator and the power supply transistor to the mounting boss of the
cast aluminum base. Wrap one end of the clip around one side of the
mounting boss, then press the other end in position using needle nose
pliers. (See figure 5 and note in figure 4 “B”).
TOP VIEW OF TRANSISTOR
MOUNTING BOSS
SPRING CLIP AROUND ONE END OF
TRANSISTOR MOUNTING BOSS
PUSH OTHER END OF TRANSISTOR SPRING CLIP
AROUND OTHER END OF TRANSISTOR
MOUNTING BOSS
CHO-THERM INSULATOR AND TRANSISTOR TO BE SECURED
BETWEEN TRANSISTOR SPRING CLIP AND TRANSISTOR
MOUNTING BOSS (SEE NOTE IN FIGURE 4 “B”)
FIGURE 5.
FIGURE 1.
FIGURE 2.
FIGURE 3.
TRANSISTOR
SPRING CLIP
MUST PRESS
AGAINST THIS
PART OF THE
TRANSISTOR
“B”“A”
FIGURE 4.