® ION™ Light

www. .com
ENGINEERING COMPANY INC.
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: (860) 526-9504
Sales Email:[email protected]
Canadian Sales:[email protected]
Customer Service:[email protected]

Safety First
This document provides necessary information to allow your Whelen product to be properly and safely installed. Before beginning the installation and/or operation of this
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 ! Do not attempt to activate or control this device in a hazardous driving situation.
automotive electronics, systems and procedures.
! If this product uses a remote device to activate or control this product, make sure that this
! Whelen Engineering requires the use of waterproof butt splices and/or connectors if that control is located in an area that allows both the vehicle and the control to be operated
connector could be exposed to moisture. safely in any driving condition.
! Failure to use specified installation parts and/or hardware will void the product warranty! ! 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
! If mounting this product requires drilling holes, the installer MUST be sure that no vehicle and/or eye damage could result..
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 any holes and remove ! Use only soap and water to clean the outer lens. Use of other chemicals could result in
any metal shards or remnants. Install grommets into all wire passage holes. premature lens cracking (crazing) and discoloration. Lenses in this condition have
significantly reduced effectiveness and should be replaced immediately. Inspect and
! Do not install this product or route any wires in the deployment area of your air bag. operate this product regularly to confirm its proper operation and mounting condition.
Equipment mounted or located in the air bag deployment area will damage or reduce the Do not use a pressure washer to clean this product.
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 ! WARNING! All customer supplied wires that connect to the positive (+) terminal of the
User/Installer assumes full responsibility to determine proper mounting location, based battery must be sized to supply at least 125% of the maximum operating current and
on providing ultimate safety to all passengers inside the vehicle. FUSED “at the battery” to carry that load. DO NOT USE CIRCUIT BREAKERS WITH THIS
PRODUCT!
! 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 ! FAILURE TO FOLLOW THESE PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN
be connected directly to the NEGATIVE (-) battery post. DAMAGE TO THE PRODUCT OR VEHICLE AND/OR SERIOUS INJURY TO YOU AND YOUR
PASSENGERS!

Mounting (Standard Bracket)

#8 x 1/2 Mounting Standard Gripper Bracket
1. Place the bracket against the mounting surface and mark the two mounting hole locations. Sheet Metal Bracket Bracket (side view)
Confirm that no vehicle parts could be damaged by the drilling process. Screw (side view)
Protective
2. Using an appropriately sized bit, drill two mounting holes sized for a #8 sheet metal screw. A wire Pad
passage hole may also be needed. De-burr this hole and install a grommet to protect the wires.
NOTE: VHB adhesive tape is provided as an alternative to securing the ION™ with screws.
Remove the protective backing from this tape and press it firmly onto the bottom of the bracket as
shown. Clean the mounting surface with a 50/50 mix of isopropyl alcohol and water and dry Mounting
thoroughly before mounting the bracket onto the mounting surface. VHB Tape
(optional) Surface
3. Route the wires through the hole in the bracket and through the wire passage hole. Secure the
ION™ to the bracket using the hardware provided. Wire as outlined below.
Cable Gripper
Mounting (Gripper Bracket) Standard
Bracket Bracket
1. Apply the protective pads to the bracket in the location shown (side view). Secure the ION™ to #6-32 x 5/16
the bracket in the same fashion as outlined for the standard bracket. Screw
2. Position the bracket onto the proposed mounting surface as shown. Apply a drop of Loctite 222
to the threads of the #6 x ½" PPHMS provided.
3. Thread these screws into the underside of the bracket as shown and secure the bracket to the
mounting surface.
Wiring #6-32 x 1/2
WHT / VIO Scan-Lock™ Screw
GRY SYNC
BLK
LED Color
Switch* Fuse* Shield
(SP/ST) (3 AMP) (+) (-) Bracket
#6-32 x 5/16
*Customer Supplied 12V Battery Screw
Operation IMPORTANT!
The membrane shown must
Scan-Lock™(WHT/VIO) - To advance to the next pattern, apply +VDC to the WHT/VIO wire for less always face downwards!
than 1 second. To cycle backwards, apply +VDC for more than 1 second. To reset to the factory default
pattern, turn off power to the lighthead. While applying +VDC to the WHT/VIO, turn the lighthead back on. Do not cover, obstruct or
Continue to apply voltage for 5 seconds. remove this membrane Flat
regardless of mounting style! Washer
Lightheads configured to display the Phase 1 mode of a pattern will flash simultaneously. Any lightheads
configured to display the Phase 2 mode will alternate with any Phase 1 lightheads with the same pattern.
Sync (GREY) - To sync two lightheads, configure both lightheads to display the same Phase 1 pattern. 1/4-20 Elastic
With the power off, connect the GREY wires from each lighthead together. When the lightheads are
#10 x 1/2 Stop Nut
PPHSMS
activated, their patterns will be synchronized. To configure the two lightheads to alternate their patterns,
advance the pattern of either lighthead to the Phase 2 mode of the current pattern.
To understand how to use the sync feature with more than two lightheads, the principles will be applied to a
sample system consisting of 4 lightheads with 2 mounted on the rear, driver-side and 2 mounted on the Bail
rear, passenger-side. With all the wiring complete, turn on all 4 lightheads. As shipped from factory, the Bracket
lightheads will all display SignalAlert™ 75 - Phase 1. To configure one side to alternate with the other side,
change the pattern for either the passenger or driver side to Phase 2 mode for that pattern.
IMPORTANT! SYNC-capable LED lightheads can be SYNCed to a SYNC-capable strobe power supply
(such as the CS240S or UPS64LXA) by wiring their GREY wires together. When connected, LED
lightheads in Phase 1 of a pattern will flash simultaneously with strobe lightheads connected to the
Flash Patterns:
GREEN wire outputs. LED lightheads set to Phase 2 of a pattern will alternate with strobe lightheads NOTE: BOLD = California Title XIII Compliant Pattern
connected to the WHITE wire outputs. GREEN wire outputs always alternate with WHITE wire outputs.
Italic = SYNC Pattern PH 1 = Phase 1 PH 2 = Phase 2
Phase Operation: 1. SignalAlert™ 75 PH 1 9. ComAlert™ 75 PH 1 17. SingleFlash 120
PHASE 1 PHASE 2 2. SignalAlert 75 PH 2 10. ComAlert 75 PH 2 18. SingleFlash 300
BOTH sides flash together (ON-OFF-ON). BOTH sides flash together (OFF-ON-OFF). 3. CometFlash® 75 PH 1 11. LongBurst™ 75 PH 1 19. DoubleFlash 150
4. CometFlash 75 PH 2 12. LongBurst 75 PH 2 20. ComAlert™ 150
ON ON OFF OFF 5. DoubleFlash 75 PH 1 13. PingPong™ 75 PH 1 21. ActionFlash™ 50
Note: 6. DoubleFlash 75 PH 2 14. PingPong 75 PH 2 22. ActionFlash™ 150
OFF OFF ON ON Phases 1 & 2 are 7. SingleFlash 75 PH 1 15. SingleFlash 60 23. ModuFlash™
ON ON OFF OFF visually indentical. 8. SingleFlash 75 PH 2 16. SingleFlash 90 24. ActionScan™
25. Steady
IMPORTANT! It is the responsibility of the installation technician to make sure that the installation
and operation of this product will not interfere or compromise the operation or efficiency of any IMPORTANT WARNING!
vehicle equipment! CAUTION! DO NOT LOOK DIRECTLY AT THESE LEDS
Before returning the vehicle to active service, visually confirm the proper operation of this product, WHILE THEY ARE ON. MOMENTARY BLINDNESS AND/OR
as well as all vehicle components and/or equipment. EYE DAMAGE COULD RESULT!

©2010 Whelen Engineering Company Inc.

Form No. 14435D (041515)
For warranty information regarding this product, visit www.whelen.com/warranty
 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 he can operate the system without
taking his 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.