Whelen Engineering Company 2022 Series User manual

Page 1
©1999 Whelen Engineering Company Inc.
Form No.13437F (102207)
Installation Guide:
2022 Series Strobe Beacons
(Polycarbonate Base)
51 Winthrop Road
Chester, Connecticut 06412-0684
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
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 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!
®
ENGINEERING COMPANY INC.
For warranty information regarding this product, visit www.whelen.com/warranty

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#4 X 1/2"
PHILLIPS PAN
HEAD SMS
PCB
ASS'Y
OPTIC
DOME
BASE
#10X5/8"
PPH SMS
FASTEX
GROMMET
When inserting the flash
tube assembly into the
strobe power supply
assembly, align the 3
prongs on the flash tube
with the slots in the
power supply.
BASE
SEAL
#6 X 5/8" PAN HD.
THX HD. SCREW
#6 X 5/16" HEX WSHR
HD THD FORM. SCREW
FLASH
TUBE
ASS'Y
IMPORTANT:
Keep drain hole
in base facing
rear of vehicle.
HI /LOWGH POWER
If you wish to control Hi/Low Power
externally, cut the VIOLET wire off at this
point and exit with the BLACK and RED
wires. Ground this wire to go to high
power. You may install an SPST switch
(customer supplied).
FLASH PATTERN SELECTION
To achieve any of the 4 flash patterns,
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 beacon
will default to QuintFlash.
PCB ASSEMBLY (COMPONENT SIDE)
JU1
BLK
JU2
RED
JU6
QuintFlash
DoubleFlash
RapidRandom
ActionFlash™
JU1 JU2
IN
IN
CUT
CUT
IN
CUT
IN
CUT
FLASH PATTERNS
FLASH PATTERN SELECTION
HI/LOW POWER CONTROL
O-RING
GASKET
Assembly and Operation:
Specifications:
Input Voltage.................................................................. 12.8 / (25.6) VDC
Input Current..................................................2.5 Amps & 1.25 Amps avg.
Input Power............................................................................... 31.5 Watts
Flashrate: QuintFlash™.......................... 72 QuintFlashes (5) Per Minute
DoubleFlash .......................... 115 Double Flashes Per Minute
RapidRandom......................150-370-150 Flashes Per Minute
ActionFlash ....... 1 QuintFlash & 4 Single Flashes Per Minute
Energy ........................................................8.6 / 2.5 / 2.5 / 2.5 / 2.5 Joules
Output Power............................................................................... 22 Watts
WARNING!The strobe power supply is a high voltage device. Do not
remove flash tubes or dismantle the strobe light head
assembly while in operation. Wait 10 minutes after turning
power off before starting work or trouble shooting.
Mounting:
1 Inch (NPT) Pipe Mount:
1. Threading for a 1 inch (NPT) pipe mounting is precast in the base.
Feed power cable through pipe and connect cable to beacon.
2. Screw strobe beacon to threads on the pipe, taking precaution not to
damage the power wires. NOTE: Do not tighten base too hard
onto pipe so as not to damage the threads on the base.
Permanent Mount:
1. Use the base as a template and mark the three mounting holes onto
the mounting surface. After removing the base, mark in the center
between the 3 mounting holes, the location of the wire access hole.
2. Drill the mounting holes using a #16 drill bit. Drill a wire access hole
using a 3/8” drill bit. Remove the burrs from the wire access hole so
as not to damage the wires. It is recommended that you install a
rubber grommet to further protect the wires. A gasket will be used
between the beacon base and the mounting surface.
3. After connecting the beacon to the 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 mounting holes in the mounting surface. Secure beacon firmly to
the mounting surface with the #10 X 5/8 Sheet Metal Screws.
Temporary Mount:
Magnetic/suction: Thoroughly clean the proposed mounting surface prior
to mounting. For suction cup mounting, wipe the suction cup clean, place
the beacon onto its mounting surface and apply gentle pressure to ensure
a good seal. The Magnetic/Suction Cups mount the same way as
standard suction cups but are best suited to a flat, steel surface.
Magnetic: Place beacon onto mounting surface and plug into cigar lighter.
WARNING! Beacons equipped with cigar cords are intended for
shortduration, intermittent operation only! Prolonged
operation requires the beacon to be wired to the vehicle.
WARNING! The presence of any temporarily mounted warning light
on the outside of a vehicle in motion is not
recommended and is at the sole discretion and liability
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 the load. DO NOT USE CIRCUIT
BREAKERS WITH THIS PRODUCT!
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 beacon, in the positive (+) wire (RED) and must be
fused at the battery. A 7.5 AMP Fuse is Recommended for this unit.
1. Connect the RED wire on the beacon to positive voltage (+). A
customer supplied single pole single throw (SPST) switch may be
used to control the ON/OFF function of the beacon.
2. Connect the BLACK wire on the beacon to a negative (-) ground.
10-24
ELASTIC
STOP NUT
(QTY 4)
10-24 X 5/8
U-BOLT
(QTY 2)
1. Secure the bracket to the mirror
2 supplied U-Bolts and elastic1.
or other part of the vehicle using the
stop nuts.
Mirror Mount Bracket
10-24 X 7/8
PPHMS
(QTY 3)
10-24
ELASTIC
STOP NUT
(QTY 3)
2. using the supplied sheet metal
screws
Secure the Beacon to the bracket
and elastic stop nuts.2.

Page 3
01-0683147LAV
25-0510523-05
14-130216-160
06-143328-000
13-130111-073
69-1340052-00
08-1583927-05
38-0441331-00
68-2180452-10
01-0683147LAP
15-065410-100
36-0341567-00
15-041416-080
02-0168306-00
06-181468-001
38-0241596-00
68-2180483-10
15-101416-100
01-0461585-00
15-066939-056
06-182589-001
01-0683147HAP
01-0683147LAM
1
1
111
1
11
1
1
11
2
1
STROBE LIGHT ASSY MODEL 2022MP/VP422MP/
STROBE LIGHT ASSY MODEL 2022LV/
STROBE LIGHT ASSY MODEL 2022LP/
STROBE LIGHT ASSY MODEL 2022HP/
SUCTION CUP / MAGNET SUCTION CUP MOUNT
#6 x 5/16" HEX WASHR HD. THD. FORMING SCREW
DOME AMBER HIGH//
FLASH TUBE ASS'Y FTU 20W/
#4 X 1/2" PHILLIPS PAN HD SMS SS
PCB ASSY MODEL 2022 SERIES/
BASE STROBE PLASTIC//
SEAL-BASE MODEL 2000 SERIES B/
#10 x 5/8" PPH SHEET METAL SCREW
#6 X 5/8" PAN HD. THD. FORM SCREW
DOME AMBER/
BUTT TERMINAL #34071
1/4-20 X 1" PPHMS SS SCREW
BASE VACUUM MOUNT STROBE LIGHT ASS'Y/
1/4-20 WIZ CAD PLATED NUT
CIGAR CORD PORTABLE/
O-RING ROTATING BEACON ASSEMBLY/
KIT MAGNET MOUNT 2000 SERIES B//
BASE STROBE PLASTIC MAG. MT.///
2
3
ITEM PART NUMBER DESCRIPTION
QTY QTY QTY QTY
14
15
18
20
21
22
24
25
26
4
6
7
8
9
10
13
1
111
1
1
1
11
1
1
1
1
2
3
2
3
1
1
2
3
2
1
2
3
2
3
2
3
2
1
1
1
1
BLACK / GROUNDRED / +12 VDC
1" NPT PIPE
13
4
8
6
4
8
7
7
3
2
18
9
1
10
6
3
2
22
18
12
25
26
22
21
20
24
(2) BUTT
TERMINALS
POWER
SUPPLY
WIRING DIAGRAM
RED BLACK
GROOVED
SMOOTH
GROMMET
1/4X11/4PHSMS
PHILLIPS TYPE AB
1/4 SPLIT
LOCKWASHER
MAGNET
SEE WIRING
DIAGRAM
SEE WIRING
DIAGRAM
MAGNETIC MOUNT
OPTION
CIGAR PLUG
& CORD
FOAM GASKET
15
14
SUCTION/MAGNET MOUNT
OPTION
PERMANENT MOUNT
OPTION
DOME:
H - HIGH DOME
L - LOW DOME
BASE:
P - PERM MOUNT
M - MAGNETIC MT.
V - VACUUM MT.
COLOR:
R - RED
B - BLUE
G - GREEN
A - AMBER
C - CLEAR
V - VIOLET
DOME
HEIGHT
PART N0. KEY: BASIC PART NUMBER
+ 3 LETTERSPART N0. KEY:
01-0683147___
COLOR BASE
TYPE
STROBE LIGHT BEACON / MODEL 2022 / PARTS
MTG. HOLES FOR
#10 SCREWS (3)
3/8" DIA. WIRE
ACCESS HOLE
5.937" DIA. B.C.
MOUNTING DIMENSIONS
PERMANENT MOUNT
WIRING DIAGRAM
ALL FUSES AND SWITCHES
ARE CUSTOMER SUPPLIED
(+)
Battery
(-)
BLACK / GROUND
VIOLET / HI/LOW
RED / POSITIVE
SPST
SWITCH
SPST
SWITCH
5 AMP FUSE