®

ENGINEERING COMPANY INC.

51 Winthrop Road

Chester, Connecticut 06412-0684

Phone: (860) 526-9504

Internet: www.whelen.com

Sales e-mail: [email protected]

Customer Service e-mail: [email protected]

Installation Guide:

Legacy® Mini-Lightbar

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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.

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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.

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!

©2014 Whelen Engineering Company Inc.

Form No.14786F (050219)

For warranty information regarding this product, visit www.whelen.com/warranty

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IMPORTANT! The lightbar must be a minimum of 16" from any radio antennas.

NOTE: There may be a roof support member that spans the distance between the driver’s and passengers side. DO NOT DRILL THROUGH

THIS MEMBER! Adjust the location until the holes can be drilled without contacting this support member.

Caution: Permanent mounting of this product will require drilling.

It is absolutely necessary to make sure that no other vehicle components could be damaged by this process. Check both sides of the mounting surface before starting. If damage is likely, select a different mounting location.

Permanent Mounting:

1.

Install the mounting bracket to the mounting foot using the supplied

5/16 Flat Washers and 5/16 - 18 Elastic Stop Nuts (Fig. 1). Do NOT install the optional spacers yet.

2.

Place the bracket into the track on the bottom of the extruded base of the lightbar and twist it into position (Fig. 2).

Fig. 1

MOUNTING

BRACKET

2 DEGREE SPACER

MOUNTING FOOT

MOUNTING

PAD

5/16 FLAT

WASHER

5/16 - 18

E L A S T I C

STOP NUT

Insert round side of bracket under lip in extrusion

Secure bracket with allen set screws (QTY 4)

3.

Slide the bracket to the outer end of the base extrusion and secure the bracket to the extrusion using the four 1/4 - 20 X 1/2 ALLEN SET

SCREWS (Fig. 2). Repeat steps 1 - 3 for other side of lightbar.

4.

Installing Spacers: Spacers are used as required to adjust the lightbars clearance from the vehicle roof. Spacers are also used to make the lightbar level with the road so that the light does not project up or down when viewed from the front or rear of the vehicle. Each spacer creates a 2° incline.

rear of vehicle

Light must project straight out from front and rear

Be sure vehicle is parked on a level surface

SPACER front of vehicle

VEHICLE ROOF

Fig. 2

Swing other side of bracket under other lip

Lightbar angle: Place the lightbar onto the vehicle roof in its exact mounting location and use a level to check the angle of the lightbar. If (because of the

SIDE VIEW curvature of the vehicle roof) the front and rear lights project up or down, you

Stack 2 spacers face to face to raise the height of the lightbar .

will need to install one of the supplied spacers. Note the angle of the tilt to determine where to place the spacer.

Installation: Remove the mounting feet (not the bracket) and install the spacer (maximum 1 per side) then reinstall the feet.

Distance from roof: The lightbar must be no closer than 1/2 inch (at the closest point) from the vehicle roof.

Installation: Remove the mounting feet

(not the bracket), install the spacers as shown (maximum 2 per side) and reinstall feet.

5.

Position the lightbar onto the vehicle in its exact mounting location and mark the location of the mounting holes onto the mounting surface using the mounting feet as templates.

If the permanent mounting holes in the mounting feet are difficult to access, you can use the measuremen ts shown here to mark off and drill the mounting holes. You

6½"

6½"

1 / 4 - 2 0 X 1 1 / 2 "

SOC K E T HEA D

SCREW

PERMANENT

M O U N T I N G will also need to measure the distance between the mounting feet for your application since lightbar width will depend on the lightbar you are mounting.

6.

Remove the lightbar and drill the

4 mounting holes.

7.

Install the lightbar using the supplied 1/4 - 20 X 1-1/2" Socket

Head Screw, 1/4” Internal Tooth

Lock Washer and 1/4 - 20 X 7/16

Hex Nut.

MOUNT I NG

S U R FA C E

1 / 4 "

I N T ERNAL T OO T H

LOC K WASHER

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1 / 4 - 2 0 X 7/ 16

HE X NU T

Fig. 1

Bottom of

Extrusion

1/4 - 2 0 X 5/8 Square

Hd Set Screw

1/2 - 13 Hex Bolt

1/2 " Split Lock Washer

1/2 " Flat Washer

MOUNTING

SURFACE 1/2 - 13 X 2-3/4

Hex Head Bolt

Mounting

B r a c k e t

IMPORTANT! The lightbar should be located a minimum of 16" from any radio antennas!

Slide Bolt Mounting:

1.

2.

3.

4.

5.

6.

Insert the two supplied 1/2 - 13 X 2-3/4 HEX HD BOLTS into the slide bolt brackets and twist the two brackets into the bottom of the lightbar extrusion

(Fig. 1).

With the slide bolt brackets in their mounting position, secure them to the lightbar with the supplied set screws.

Position the lightbar onto the vehicle and mark the location of the two mounting bolts off onto the mounting surface.

Remove the lightbar and drill the two mounting holes you marked off using a 1/

2” drill bit.

Secure the lightbar to the mounting surface with the supplied mounting hardware.

Extend wires to your switch panel and refer to the wiring diagram. Refer to the instructions included with your switches for switch wiring.

Wiring and Operation:

Extend the control cable to your switch panel and make connections. The control cable connects to your control head or switch box and is fused there. Applying

+12VDC to a control wire will activate its function.

BLACK and WHT/BLK are ground wires. (Optional

Alley/Take-down cable not included with standard model also shown).

Cigar Plug: In models that feature a cigar plug, you can control Scan-Lock pattern selection and

Power with the 2 switches located on the top of the plug.

Ci ar Cord Switch

RED LED

SW1 SW2

SW1 -

SW2 -

N/O 10 AMP switch with LED

Indicator (On-Off)

N/O 10 AMP

Momentary Switch

(Scan-Lock™)

Legacy™ Mini-Lightbar

Wirin g

All fuses and switches are customer supplied

Wire Color Function

WHT/BL

K Ground

BL

K Ground

RE

D Front Corners (+12V D C)

BLU

ORANGE

WHT/ORG

Rear Corners (+12V D C)

D irectionals Front (+12V D C)

D irectionals Rear (+12V D C)

SPST

Switch

BRN

WHT/GRN

Low Power

Scan-Lock™

Momentary Switch

S P S T

Switch

Wire Color Function

BROWN

WHT/BL

BLU

YEL/GRN

WHITE

K

( Ground) D river & Passenger Alleys

( Ground) Take D owns

(+12V D C) Take D owns

(+12V D C) Passenger Alley

(+12V D C) D river Alley

5 Amp

Fuse

(+)

S P S T

Switch

3 Amp

Fuse

RED / Front Corners:

Apply +12VDC to the RED wire to activate the Front Corner lights.

BLUE / Rear Corners

Apply +12VDC to the BLUE wire to activate the Rear Corner lights.

ORANGE / Front Directionals:

Apply +12VDC to ORG wire to activate the Front Directional lights.

WHT/ORG / Rear Directionals:

Apply +12VDC to WHT/ORG wire to activate the Rear Directional lights.

BROWN / Low Power:

The switch type used depends on how you wish Low Power to function:

Battery

(+)

Battery

(-)

(-)

Temporary Magnetic/

Suction Cup Mounting:

The magnetic/suction cup should be mounted on a flat part of the roof.

Magnetic/suction: Thoroughly clean the proposed mounting surface prior to mounting. Wipe the suction cup clean, place the beacon onto its mounting surface and apply gentle pressure to ensure a good seal has been achieved.

WARNING! The use of any magnetically mounted warning device on the outside of a vehicle in motion is not recommended and is the sole risk and responsibility of the user.

IMPORTANT! It is the responsibility of the installation technician to make sure that the installation and operation of this product will not interfere with or compromise the operation or efficiency of any vehicle equipment! Before returning the vehicle to active service, visually confirm the proper operation of this product, as well as all vehicle components/equipment.

Latching Mode: Apply +12 VDC to the BROWN wire for less than 1 sec. to “latch” the lightbar into Low Power . The unit must be turned off and then back on to restore normal operation. (Momentary Switch)

Level Mode: Apply +12 VDC to the BROWN wire for over 1 sec. to hold the lightbar in Low Power until voltage is removed. (Toggle Switch)

WHITE-GREEN / Scan-Lock™:

The WHT/GRN wire allows you to choose from available flash patterns. You must activate the function to select a pattern:

TO CYCLE THROUGH ALL PATTERNS:

To cycle forward apply +12 VDC to the WHT/GRN wire for less than 1 second and release.

To cycle backward apply +12 VDC to the WHT/GRN wire for more than 1 second and release.

TO SET A PATTERN AS DEFAULT:

When the pattern is displayed, allow it to run for more than 5 seconds. The lighthead will now display this pattern when activated.

TO RESET TO THE FACTORY DEFAULT PATTERN:

With power off, apply +12 VDC to WHT/GRN wire while turning power on.

Use a normally open momentary switch for Scan-Lock operation

FLASH PATTERNS:

1. SignalAlert™ L/R SYNC

2. SignalAlert™ L/R ASYNC

3. SignalAlert™ IN/OUT

4. SignalAlert™ SIM

5. SignalAlert™ ALT/SIM

6. CometFlash® L/R SYNC

7. CometFlash® L/R ASYNC

8. CometFlash® IN/OUT

9. CometFlash® SIM

10. CometFlash® ALT/SIM

11. DoubleFlash 75 L/R SYNC

12. DoubleFlash 75 L/R ASYNC

13. DoubleFlash 75 IN/OUT

14. DoubleFlash 75 SIM

15. DoubleFlash 75 ALT/SIM

16. SingleFlash 75 L/R SYNC

17. SingleFlash 75 L/R ASYNC

18. SingleFlash 75 IN / OUT

19. SingleFlash 75 SIM

20. SingleFlash 75 ALT/SIM

21. LongBurst™ L/R SYNC

22. LongBurst™ L/R ASYNC

L/R SYNC = LEFT / RIGHT SYNCHRONOUS

L/R ASYNC = LEFT / RIGHT ASYNCHRONOUS

SIM = SIMULTANEOUS

IN/OUT = IN / OUT

23. LongBurst™ IN/OUT

24. LongBurst™ SIM

25. LongBurst™ ALT/SIM

26. SingleFlash 60 L/R SYNC

27. SingleFlash 60 L/R ASYNC

28. SingleFlash 60 IN/OUT

29. SingleFlash 60 SIM

30. SingleFlash 60 ALT/SIM

31. SingleFlash 60 STDY LEFT

32. SingleFlash 60 STDY RT

33. SingleFlash 60 STDY BOTH

34. SingleFlash 90 L/R SYNC

35. SingleFlash 90 L/R ASYNC

36. SingleFlash 90 IN/OUT

37. SingleFlash 90 SIM

38. SingleFlash 90 ALT/SIM

39. SingleFlash 90 STDY LEFT

40. SingleFlash 90 STDY RT

41. SingleFlash 90 STDY BOTH

42. SingleFlash 120 L/R SYNC

43. SingleFlash 120 L/R ASYNC

44. SingleFlash 120 IN/OUT

45. SingleFlash 120 SIM

STDY LEFT =

STDY RT =

ALT/SIM =

46. SingleFlash 120 ALT/SIM

47. SingleFlash 120 STDY LEFT

48. SingleFlash 120 STDY RT

49. SingleFlash 120 STDY BOTH

50. SingleFlash 240 L/R SYNC

51. SingleFlash 240 L/R ASYNC

52. SingleFlash 240 IN/OUT

53. SingleFlash 240 SIM

54. SingleFlash 240 ALT/SIM

55. ActionFlash™ L/R SYNC

56. ActionFlash™ L/R ASYNC

57. ActionFlash™ IN/OUT

58. ActionFlash™ SIM

59. PingPong™ L/R SYNC

60. PingPong™ L/R ASYNC

61. PingPong™ IN/OUT

62. PingPong™ SIM

63. ModuFlash™ L/R SYNC

64. ModuFlash™ L/R ASYNC

65. ModuFlash™ IN/OUT

66. ModuFlash™ SIM

67. ActionScan™

STEADY LEFT

STEADY RIGHT

STDY BOTH = STEADY BOTH

ALTERNATING SIMULTANEOUS

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