Whelen Engineering Company OR5001V Installation And Service Manual
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Whelen Engineering Company OR5001V Installation And Service Manual

Whelen Engineering Company OR5001V Installation And Service Manual

Anti-collision light systems
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© 2015 Whelen Engineering Company, Inc.
The document reference is online, please check the correspondence between the online documentation and the printed version.
ANTI-COLLISION LIGHT
SYSTEMS INSTALLATION
AND SERVICE MANUAL
May 2015
Approved under
STC SA6NE
STC SA21NE
STC SA615EA
STC SA800EA
ISO 9001 Registered QMS
Document #05131 Rev. D

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  • Page 1 Approved under STC SA6NE STC SA21NE STC SA615EA STC SA800EA ISO 9001 Registered QMS © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 2: Table Of Contents

    INDEX INDEX PAGE Table Of Contents/Company Information Strobe System Requirements ENGINEERING COMPANY, INC. Aircraft not specifically mentioned on the eligibility list 51 WINTHROP ROAD, CHESTER, CT 06412-0684 ● PHONE: (860) 526-9504 FAX: (860) 526-2009 Strobe System Wiring Strobe Power Supply Installation Makers of Aviation, Automotive and Industrial Safety Lighting since 1953 Orion 500 LED Light Assemblies...
  • Page 3 This is an This is an approved anti-colli- approved anti-collision sys- sion system. tem. © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 4: Aircraft Not Specifically Mentioned On The Eligibility List

    AIRCRAFT NOT SPECIFICALLY MENTIONED ON THE ELIGIBILITY LIST ESTABLISHING SOLID ANGLE BLOCKAGE WITH REFERENCE TO AC ANTI-COLLISION LIGHT INSTALLATION PROCEDURES 43.13-2A, CHAPTER 4. STC SA800EA / STC SA615EA / STC SA21NE 1. To determine the vertical angles to use with reference to Figure 7 The following information is to assist in the installation of a custom and 8 of the aforementioned chapter 4, attach a long string to the Whelen anti-collision strobe light system on any aircraft, and how to...

  • Page 5: Strobe System Wiring

    A446 ... . .02-0230085-00..2 Position Female Connector with Sockets A446 © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 6: Strobe Power Supply Installation

    STROBE POWER SUPPLY INSTALLATION INSTALLATION PROCEDURES: Wiring WARNING!!! STROBE LIGHT POWER SUPPLIES ARE Location POLARITY SENSITIVE. REVERSING THE INPUT POLARITY WILL CAUSE SEVERE DAMAGE TO THE 1. Consider areas or locations designated by the aircraft man- POWER SUPPLY! ufacturer. Do not mount the strobe power supply closer than three (3) feet of the ADF loop.

  • Page 7: Orion 500 Led Light Assemblies

    ORION 500 LED LIGHT ASSEMBLIES MODEL OR5001V & OR5002V LED Tail Position /Anti-Collision Lighthead Assembly All LED self-contained tail mounted Position/Anti-Collision system. Eliminates the need for external power supplies and reduces current draw and provides thousands of hours of operation.
  • Page 8 Lens, Model 90667 (No Drain Slot, Hardcoat) * For shipping purposes only 38-0131364-00 Gasket, VHB Seal 01-0290717-00 Sub-Assy, ORION-500, Model OR5001V (12 VDC) 13-040130-040 Nut, #4-40 X 1/4, Hex Brass ORION Model OR5002V 28V Series Exploded View Parts Figure 8b...

  • Page 9: Orion 650 Led Light Assemblies

    If synchronization is not necessary, the Orange..+28VDC (POS) Yellow..SYNC 20AWG connection may be left open. Black..Ground MIL-22759/43 Wire © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 10 Model OR6501G, OR6501R 14V Series Model OR6502G, OR6502R 28V Series Exploded View Parts Exploded View Parts Figure 10a Figure 10b Lens P/N 01-0251094-00 Shown For ReferenceOnly Drain Hole Drain Hole Model OR6501G & OR6501R Series Parts List Model OR6502G & OR6502R Series Parts List ITEM PART NUMBER DESCRIPTION...

  • Page 11: Orion 650E Led Light Assemblies

    SYNC 7. Check all avionics systems for interference from this installation. BLACK GROUND © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 12 Model OR6501GE, OR6501RE 12V Series Exploded View Parts Figure 12a Model OR6501GE, OR6501RE Series Parts List ITEM PART NUMBER DESCRIPTION — 01-0790701-01 OR6501GE Wingtip Position/Anti-Collision Light, 12V (Green) — 01-0790701-02 OR6501RE Wingtip Position/Anti-Collision Light, 12V (Red) 07-771790-100 Mounting Plate, Model 90701 (Heli-Coils, CMPL) —...
  • Page 13 (64mm) TRIGGER POWER SELECTOR SYNC OUTLET Suggested Mounting Plan Figure 13b Figure 13d © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 14 Pin 1. (Top) - RED wire/anode .080” Pin 2. (Center) - BLACK wire/cathode (2mm) Pin 3. (Bottom) - WHITE wire/trigger WHELEN ENGINEERING COMPANY CHESTER, CONNECTICUT 06412-0684 OUTPUT POWER Right Connector (Power Input) (1) ANODE (1) + (2) CATHODE (2) -...
  • Page 15 .187” DIA. (4) PLACES SUGGESTED MOUNTING PLAN SUGGESTED MOUNTING PLAN FOR OPTIONAL BASE STANDARD © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 16: Led Light Assemblies - 90520( ) Series

    LED LIGHT ASSEMBLIES MODEL 90520 ( ) SERIES LED FLASHING BEACON (Red & White LED’s) TSO-C96a CLASS III APPROVED 90520 series LED beacons are FAA TSO compliant self-contained LED anti-collision lights (Ref. Class III - 100 effective candlepower). They are designed to replace strobe lightheads as small as the A470A with available models to replace HR self-contained beacons (HRCFA) or our legacy 70900 LED beacon.
  • Page 17 100° Countersink (typ) WHITE (+) 28VDC 18AWG 12” ±1.0” RED (+)14VDC 20AWG 6" ±1.0" © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 18 Models 9052004, 9052014 Dimensions Exploded View Parts Figure 18b Figure 18a 5.14” (131mm) Model 9052004 & 9052014 Parts List 2.60” (66mm) ITEM PART NUMBER DESCRIPTION — 01-0790520-04 Model 9052004 (28V) Upper — 01-0790520-14 Model 9052014 (28V) Lower 01-0290522-00 Assy, 28V 38-0250885-00 Gasket, Lens —...
  • Page 19 20AWG 6” ±1.0” Suggested Mounting Hole Pattern (+) 28VDC WHITE 18AWG 12” ±1.0” © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 20 Models 9052007, 9052017 Dimensions Exploded View Parts Figure 20b Figure 20a 3.60” (91mm) ITEM PART NUMBER DESCRIPTION — 01-0790520-07 Model 9052007 (28V) Upper — 01-0790520-17 Model 9052017 (28V) Lower 01-0290522-00 Assy, 28V 38-0250885-00 Gasket, Lens — 68-4971082A30 Lens, Clear — 68-4971082A31 Lens, Clear 07-571361-100...
  • Page 21 +28VDC WHITE BLACK MODULE MS CONNECTOR WIRING (REAR VIEW) CONNECTOR MS3102R10SL - 3P © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 22: Led Light Assemblies - 71080( ) Series

    LED LIGHT ASSEMBLIES MODEL 71080 ( ) SERIES LED BEACON (Red LED’s) LED Flashing Anti-Collision Light Assembly (150 eff. Cd) (14 VDC & 28 VDC) Anti-Collision 71080 series LED beacons are FAA TSO compliant Self-Contained LED lights (Ref. Class I - 150 effective candlepower). They are designed to replace a range of products. Refer to models and descriptions below.
  • Page 23 Assy, 28V LED Anti-Collision Light 71080 — — 07-771051-200 Plate, Adapter Model 4 Hole © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 24 Models 7108004, 7108014 Dimensions Suggested Mounting 5X Ø.156 Thru Figure 24b Exploded View Parts Figure 24a Pattern C'SINK to Ø.281 x 100° spaced as shown on 75° Ø4.656 Bolt Circle 75° 60° Mounting 75° 75° Figure 24c ∅.125 Drain Hole Lower Mount ∅5.14”...
  • Page 25 14-0050503-28 Screw, 6-32 X 3/8 PPHMS SS MS51957-28 16-0050506136 Washer, #6 Lock-Spring MS35338-136 © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 26 Models 7108008, 7108018 Dimensions Exploded View Parts Figure 26b Figure 26a ∅.125” (3mm) ∅5.14” (131mm) Drain Hole Lower Mount Only 75° 75° 17° 75° 75° Mounting Figure 26c 5x Ø.156” (4mm) thru C'SINK to Ø.281” (7mm) x 100° spaced as shown on Ø4.656”...
  • Page 27 Gasket, Adapter LED Beacon EC Style — 01-0271848-03 Assy, 28V LED Anti-Collision Light 71080 © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 28: Self Contained Light Assemblies - 70900( ) Series

    SELF CONTAINED LIGHT ASSEMBLIES TSO-C96a CLASS III MODEL 70900 ( ) SERIES APPROVED FLASHING ANTI-COLLISION LIGHT ASSEMBLY 70900 series are FAA TSO compliant self-contained anti-collision lights for fixed wing aircraft. An external power unit is not required. Conservative lab life results greater than 20,000 hours. No EMI or RFI produced. All units meet the minimum requirements stated in FAR Parts 23 &...
  • Page 29 Figure 29b Thread 115° 115° 1.00” Clearance for wires Typical Mounting Hole Pattern © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 30: Self Contained Light Assemblies - 71055( ) Series

    SELF CONTAINED LIGHT ASSEMBLIES MODEL 71055 ( ) SERIES LED BEACON ANTI-COLLISION LIGHT ASSEMBLY TSO-C96a CLASS III APPROVED 71055 series beacons are FAA TSO compliant self-contained LED Anti-Collision lights. They are designed to replace existing quartz halogen flasher beacons installed as original equipment on single engine Cessna's from 1967 and later (contact factory for details).
  • Page 31 WASHER, #4 LOCK-SPRING MS35338-135 10-0315069-13 LABEL, VOLTAGE ID +14V — 01-0271829-01 ASSY, 28V LED ANTI-COLL LT © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 32 MODEL HRCFA SERIES SELF-CONTAINED STROBE ANTI-COLLISION LIGHT ASSEMBLY ® HRCFA series is a self-contained CometFlash strobe Anti-Collision light. The unique polycarbonate optic lens and reflector design re-directs stray light rays into the horizontal plane to provide maximum 360º of uniform light coverage. Available in three different lens colors, aviation Red, aviation White and split aviation Red/White and in radio-shielded configurations.
  • Page 33 75º 75º 5.00” DIA 4.65” DIA. B.C. 18.00 ±1.00 WHITE (+) BLACK (GROUND) © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 34 STROBE LIGHTHEAD ASSEMBLIES MODEL A470A SERIES A470A series remote strobe light assembly is compatible with all Whelen power supplies. It can be installed on the fuselage or the vertical fin. The unique polycarbonate optic lens and reflector design, re-directs stray light rays into the horizontal plane to provide the maximum 360º...
  • Page 35 68-4230044-30 LENS (Clear) 2.15” (55mm) #6-32 X 5/16 SS HEX NUT (MS35649-264) A450 © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 36 MODEL A650PG/PR SERIES WINGTIP STROBE ANTI-COLLISION/POSITION LIGHT ASSEMBLY A650 PG/PR Series wingtip with Anti-Collision & Forward Position lights can be used to convert non-Whelen Position lights into a Position/Anti- Collision light system. The small size allows for mounting into a wing tip enclosure.
  • Page 37 LENS, FLASHTUBE (A612) 02-0250276-00 FLASH TUBE ASSEMBLY (A610) 02-0250276-03 FLASH TUBE ASSEMBLY (MOLEX CONNECTOR) © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 38: Led Light Assemblies - 71110( ) Series

    LED LIGHT ASSEMBLIES 71110 ( ) SERIES WING TIP LED FORWARD POSITION LIGHT STROBE ASSEMBLY 71110 series is a wing tip mounted strobe anti-collision/position light assembly utilizing LED’s for the forward position lights. The LED’s pro- vide a significant reduction in current draw over conventional position light bulbs.
  • Page 39 ASSY, POSITION/STROBE LIGHT 28V RED 71110 OPEN HOLE IN LABEL FOR DRAIN HOLES 2 PLACES 11 12 © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 40 INSTALLATION OF MODEL A612 with an A610 Flash Tube A612 glass lens and A610 flash tube are used for installing wing tip strobes in single engine Cessna’s 1972 and later. The existing position light retainer is modified to accommodate the lens, and the flash tube is mounted directly behind.
  • Page 41 Belden 8502 or 8308, has an 0.058 inch OD. — 68-2290005-34 LENS, RFI COATED (A612C) © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 42 MODEL A500A SERIES INSTALLATION A500A Series Combination Strobe/Tail Navigation light used when the wingtip Anti-Collision lights are mounted in an enclosure and can’t provide 360º of strobe coverage. It is a direct replacement for the standard Tail Position light. Available in a radio-shielded version. Voltage (14 or 28) and mounting (hori- VERTICAL HORIZONTAL zontal or vertical) must be specified when ordering.
  • Page 43 — 02-0350375-01 Flash Tube And Socket Assy (A506DM) 46-0750698-00 Pigtail Model A500A Installation © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 44: Led Light Assemblies - 71011( ) Series

    LED LIGHT ASSEMBLIES MODEL 71011 ( ) SERIES LED TAIL POSITION LIGHT ASSEMBLY 71011 series are LED tail position lights designed to replace the existing “old style” tail lights typically seen mounted on most general aviation, corporate, and helicopter applications. They have all the advantages associated with using LED’s as a light source, improved reliability, and reduced operating costs and are available with horizontal or vertical mounts with 14 Volt or 28 Volt versions.
  • Page 45 NUT, 4-40 x 1/4 HEX BRASS (for shipping) 46-0750898-00 28V PIGTAIL ASSEMBLY, 6” (BLK/WHT) 46-0750898-01 14V PIGTAIL ASSEMBLY, 6” (BLK/RED) © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 46: Led Light Assemblies - 71554( ) Series

    LED LIGHT ASSEMBLIES MODEL 71554 ( ) SERIES LED TAIL POSITION LIGHT ASSEMBLY 71554 Series in our newest LED Tail Position Light. Exact Footprint for Whelen Models A555A and 71011 Taillights. Available in horizontal or vertical mount. TSO-C30c TYPE III SO C APPROVED Model 71554( ) Specifications...
  • Page 47 Assy, 14V LED Tail Pos Light Vertical 46-0750898-01 Ass'y, 14V Pigtail 6" Blk/Red © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 48: A600 Pg/Pr Series

    MODEL A600 PG/PR SERIES INSTALLATION A600 PG/PR series wing tip anti-collision, forward position and tail tail position lights, all in one compact unit. Tail position light eliminates the need for a tail mounted position light. Available in 14 or 28 VDC and in a radio-shielded version.
  • Page 49 LENS, RFI COATED (A612C) 38-0130107-00 GASKET (A427-4) 68-2290005-30 LENS, CLEAR (A612) 10 11 Model A600 Installation © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 50: A650 Series

    MODEL A650 SERIES INSTALLATION A650 series converts W1285 position lights into a position/anti-collision system by removing the existing retainer & replacing it with the A650 assembly. Radio-shielded version available. Model A650 Specifications Model Part Exposed Description Color Approvals Weight Numbers Number Height A650...

  • Page 51: Strobe Power Supply Replacement Cross Reference Listing

    Self-Contained Strobe, DoubleFlash 14 or 28 VDC HR,DFA,14/28 Self-Contained Strobe, DoubleFlash 14 or 28 VDC (A402A lens) © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 52: Continued Airworthiness Flow Chart

    CONTINUED AIRWORTHINESS FLOW CHART Inspect Lens Excessive scratches, Replace Lens discolorations or cracking? Check Lens Mounting Loose or Tighten or missing Replace hardware? Check Operation Improper Check wiring Operation? and connections Refer to trouble-shooting procedures for strobe lights Complete Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 53: Strobe System Trouble-Shooting

    © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 54 If noise problems persist, and the procedures described have not ground circuit. Alternator, electrical motor, fuel pumps and strobe light cleared them up, please contact the Whelen Engineering Company for power supplies draw heavy current through the ground circuit of the assistance.

  • Page 55: Parts Breakdown - Aircraft Strobe Beacons

    19-170052-009 Retainer for A650 Series A copy of the Whelen warranty regarding products described on these pages may be obtained free of charge from the Whelen Engineering Company, Inc., Chester, Connecticut 06412. © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D...
  • Page 56 PARTS BREAKDOWN - AIRCRAFT STROBE BEACONS A628 A425 A425A A425A A457A-D A457B-D A628-D OPTIONAL OPTIONAL OPTIONAL SA402 A457A A457A A612 A457A A402A- ( ) 01-0450685-00 A455 A455 A455 01-0450685-00 A629 A508 A508 A435 A507 SA418-2 A506 A627 A467 A504 A441 SA406 A424 A469B...

  • Page 57: Notes

    NOTES © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 58 NOTES Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 59 U.S.A. Background Photo Courtesy of Cessna Flyer Magazine December 2008 © 2015 Whelen Engineering Company, Inc. Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 60: Winthrop Road, Chester, Ct 06412-0684

    Fax: 31-20-6533991 Fax: 905-677-2188 www.whelen.com aviation@whelen.com ISO 9001 Registered QMS © 2015 Whelen Engineering Company, Inc. Part Number 04-0105131-00 Document #05131 Rev. D The document reference is online, please check the correspondence between the online documentation and the printed version.

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