Anti-Collision Light Systems Installation and Service Manual JANUARY, 2007
Anti-Collision Light Systems Installation and Service Manual JANUARY, 2007
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Table of Contents
Page 2 Table of Contents/Company Information Page 16-26 Strobe Lighthead Assemblies
Page 3 Strobe System Requirements Page 16-17 A470A Series
Page 4 Aircraft Not Specifically Mentioned Page 16-17 A450 Series, H102 & H103 Series
on the Eligibility List Page 18-19 A650PG/PR Series
Page 5 Strobe System Wiring Page 20 A610/A612 Series
Page 6 Strobe Power Supply Installation Page 21 A625 Series
Page 7-9 Strobe Power Supplies Page 22-23 A500A Series
Page 7 HDACF Page 24-25 A600 PG/PR Series
Page 8 A490ATSC Page 26 A650 Series
Page 9 A490TCF Page 27 Strobe Power Supply Replacement Cross
Page 9 A490TCCF Reference Listing
Page 10-13 Self Contained Light Assemblies Page 28 Continued Airworthiness Flow Chart
Page 10, 11 70900 Series Page 29-30 Strobe System Troubleshooting
Page 12, 13 71055 Series Page 31-32 Parts Breakdown
Page 14, 15 HRCFA Series Page 33-49 Appendix A
Page 14, 15 SACFA Series Page 50 Notes
2 Document #05131A
INTRODUCTION TO WHELEN ANTI-COLLISION STROBE LIGHTING POSITION LIGHTS AND ANTI-COLLISION LIGHT
SYSTEMS, STC SA800EA/STC SA615EA/STC SA6NE/ DISTRIBUTION PATTERNS REQUIREMENTS
STC SA21NE 360º +75º
+30º +30º
Whelen’s Anti-Collision Strobe Light Systems are approved under STC
SA615EA, STC SA800EA, STC SA6NE, and STC SA21NE, manufactured under
PMA as an approved anti-collision light for all aircraft, when installation is
accomplished in accordance with the following instructions.
Whelen’s Anti-Collision Strobe Light Systems are designed and approved
specifically for General Aviation Aircraft, to comply to FAR 91.205(c) (3) (visu-
al flight rule night) requirements.
-30º -30º
Whelen’s approved Anti-Collision Strobe Light Systems can be installed on all -75º
aircraft by completing the installation with reference to this Installation and
An approved anti-collision An approved anti-collision
Service Manual, and the appropriate technical data listed below: strobe light system must proj- strobe light system must proj-
ADVISORY CIRCULAR 43.13-1A, Chapter 11, Sections 1, 2, 3 and 7, ect light 360° around the air- ect light + or - 30° above and
Electrical Systems. craft’s vertical axis. One or below the horizontal plane of
more strobe lights can be the aircraft. One or more
ADVISORY CIRCULAR 43.13-2A, Chapters 1 and 2, Radio Installations. used. strobe lights can be used. The
+ or - 75° projected light is
ADVISORY CIRCULAR 43.13-2A, Chapter 4, Anti-Collision Light Installations. required since July 18, 1977.
ADVISORY CIRCULAR 20.21, 12-3-64, Application of Glass Fiber
Laminates in Aircraft. Approved light pattern in RI
the horizontal plane. BE 0º G
HT
The anti-collision Position Position
N GT I P S T R
wingtip mounted lights
W IN
Red Green
ANTI-COLLISION AND POSITION LIGHT REQUIREMENTS, must converge within
1200 feet directly in 110º 110º
G TI P S
LOCATIONS, & DISTRIBUTION PATTERNS front and rear of the
E
IF RE
RAG
All aircraft must have an approved anti-collision light and position light system aircraft on center line. Tail Tail
WI
If the wingtip strobe Position Position
for nighttime operations. The position lights consist of an Aviation Red on the
TR
White White
QU
light convergence is
FT
E
left side, an Aviation Green on the right, and an Aviation White taillight (REF. FAR
O
70º 70º
OV
greater than 1200 ft. in
BE
180º
I
ED LE
R
23.1389).
C
back of the aircraft, TH E
The anti-collision lighting system is required under FAR PART 91.205(c)(3). a 3rd light is necessary. I RD OB
There are different requirements affecting different aircraft. These aircraft are TAIL STR
categorized by the date of application for type certificate. Home built aircraft are
determined by the date of issuance of the Experimental Operating Limitations.
The different categories are as follows:
LOCATIONS ON THE AIRCRAFT FOR
Aircraft for which type certificate was applied for after April 1, 1957 to ANTI-COLLISION STROBE LIGHTS, TO COMPLY
August 10, 1971:
These anti-collision systems must produce a minimum of 100 effective candela
TO THE LIGHT PATTERN REQUIREMENTS.
in Aviation Red or White (REF. FAR 23.1397), 360º around the aircraft’s vertical
axis, 30º above and below the horizontal plane (REF. FAR 23.1401).
Aircraft for which type certificate was applied for after August 11, 1971 to
July 18, 1977:
These anti-collision systems must produce a minimum of 400 effective candela
in Aviation Red or White (REF. FAR 23.1397), 360º around the aircraft’s vertical
axis, 30º above and below the horizontal plane (REF. FAR 23.1401).
Aircraft for which type certificate was applied for after July 18, 1977:
These anti-collision systems must produce a minimum of 400 effective candela
in Aviation Red or White (REF. FAR 23.1397), 360º around the aircraft’s vertical
axis, 75º above and below the horizontal plane (REF. FAR 23.1401).
*The position lights must be wired independently of anti-collision lights. VERTICAL FIN WINGTIP
One anti-collision strobe light Two wingtip strobe lights that
mounted on the vertical fin will protrude beyond the wingtip,
meet the minimum require- their light converging in front
ments on most aircraft. A half and back of the aircraft within
GENERAL AVIATION MINIMUM POSITION LIGHTING red and half white lens is re- 1200 ft. is an approved anti-
REQUIREMENTS commended. collision strobe light system.
For compliance to FAR Part 23.1385 through 23.1397, VFR flight rule night
requirements on a General Aviation aircraft, you must have a TSO,d Aviation Red
forward position light on the left and an Aviation Green forward position light on
the right. See Figure 7, page 4.
These are normally mounted on the most outward extremity of the airframe so
they can project their light directly in front of the aircraft 0 degree to 110
degrees left and right horizontally, and 180 degrees up and down vertically,
unobstructed by any part of the aircraft.
The tail position light must project its Aviation White light toward the rear of the
aircraft, 70 degrees horizontally left and right from 0 degree straight back
behind the aircraft, 180 degrees up and down, 0.04 Steradian (131.36 sq.
degrees) interference is allowable, reference FAR Part 23.1387(c). More than FUSELAGE
ENCLOSED WINGTIP In a fuselage mounted anti-
one light is acceptable. Enclosed wingtip anti-collision collision strobe light system, a
strobe lights, require a third minimum of two strobe lights
strobe light on the tail or verti- are necessary to get the
cal fin, to fill in the required required vertical coverage.
light envelope. This is an This is an approved anti-colli-
approved anti-collision system. sion system.
4 Document #05131A
STROBE SYSTEM WIRING
Interconnecting Cable Intermixing Strobe Light System Equipment
1. The Whelen interconnecting cable shall be secured in place with Observe Color and Pin Numbers
approved aviation techniques.
2. The cable shall not parallel ADF, Gyro or Flux Gate compass Cables Connecting Strobe Lights MUST BE Connected
leads closer than 12 inches. Correctly!
3. Reference should be made to AC 43.13-1B, Chapter 11, Sections Whelen Engineering and Aero-flash wiring between light assemblies
3 and 7, when routing and fishing the interconnecting cable. and remote power supplies are identical as pictured below in Figure 5B.
4. Leave a service loop at the strobe lighthead end, to allow access CLIP
to the connector for flash tube replacement without having to dis-
assemble the aircraft. SHIELD*
5. CABLE COLORING CODE:
PIN 1 RED - (Anode) TE
HI
W
PIN 2 BLACK - (Cathode, flash tube ground) K
AC
PIN 3 WHITE - (Trigger) BL
TE SHIELD
HI
W
K
AC K
BL AC
BL
Figure 5A E
IT
A441 PINS POWER SUPPLY END WH
RED A442 SOCKETS FLASH TUBE END
Figure 5C
Observe Color and Pin Numbers
RED
The retaining clip on the side of each pin or socket of the A441 and
A442 connector assemblies must be bent out (Reference illustration, Both Grimes and SDI sometimes use MS (Cannon Type)
Figure 5A shown above) so that they positively snap into the AMP 3 connectors:
position socket nylon connector housing.
If it is not possible to get a good grip, it is recommended that the pins Position A = RED (Anode), Position B = White or Blue
and sockets be soldered to prevent burning of the wires. (Trigger), Position C = (Cathode) Black or Yellow
A441
REPLACEMENT CONNECTORS
Model Number Part Number Description
A441 . . . . . . . . . . . .01-0430011-00 . . . . .3 Position Male Connector with Pins
A442 A444
A442 . . . . . . . . . . . .01-0410823-00 . . . . .3 Position Female Connector with Sockets
A444 . . . . . . . . . . . .02-0230007-00 . . . . .2 Position Male Connector with Pins
A446 . . . . . . . . . . . .02-0230085-00 . . . . .2 Position Female Connector with Sockets
A446
6 Document #05131A
MODEL HDACF
STROBE POWER SUPPLY ASSEMBLY
FAA/PMA APPROVED
Specifications
Model Number . . . . . HDACF
Part Number . . . . . . . 01-0770028-05
Current Draw . . . . . . 7.0 Amps @ 14 Volts D.C.
3.5 Amps @ 28 Volts D.C.
Weight . . . . . . . . . . . 2.1 lbs.
Length . . . . . . . . . . . 5.50”
Height. . . . . . . . . . . . 2.37”
Operation Dimensions
This power supply will operate up to 3 strobe lighthead assemblies.
When operating two lights in the alternating mode, 42 joules of power 5.03
are produced for each light. While in simultaneous mode, power to
each light is 21 joules. When operating 3 lights, strobe outlet 1 pro-
duces 42 joules of power and alternates with strobe outlets 2 & 3 (pro-
ducing 21 joules each) that flash simultaneously (see Figure 7B).
Jumper to be inserted
3 2 1
ALT
SYNC
PIN
(1) + 1 TYP. 1 2 3
(2) - 2 TYP.
(3)N/C 3 TYP.
RED (+14/28V)
BLACK (-) GROUND 2.37 (MAX)
Trigger Function PIN #3 N/C
Jumping pins 1 and 2 on the trigger plug will provide an alternating
flash pattern between strobe outlet 1 and strobe outlet(s) 2 and/or 3.
Installing a switch in series with the jumper will allow strobe outlets 2 Figure 7C
& 3 to be turned off, while strobe outlet 1 remains on (see Figure 7B).
Mounting
Switch normally closed OFF
1/10 amp rated .203” DIA. (4) PLACES
ON
Jumper inserted into
trigger selector outlet 6.00”
-
14V or 28V
STROBE OUTLETS
+
2.50”
TRIGGER POWER
#3 #2 #1 SELECTOR IN
SYNC OUTLET
ALT
Operation Dimensions
This power supply will operate ONE strobe lighthead assembly at 34 6.25”
joules of power. It is equipped to flash up to five (5) other like units
5.00”
simultaneously when an 18 gauge wire is connected to outlet 3 on the
input power connector.
3.12”
OUTPUT POWER
1 - Anode 1 - (+)
2 - Cathode 2 - (-)
3 - Trigger 3 - SYNC .65”
.95”
1 1
2 2 POS. 1 (+), RED
3 3 POS. 2 (-), BLACK
POS. 3 - SYNC
Figure 8A 3.14”
Looking at the power supply connectors with the mounting plate flat on
a bench, the left connector is the strobe outlet. The right connector is
the power input and synchronization.
Left Connector (Power Output)
Pin 1. (Top) - RED wire/anode .080”
OUTPUT POWER
Mounting
5.675 MTG.
5.562 MTG.
1.600” .938”
MTG. MTG.
.187 DIA.
(8) MOUNTING HOLES
Figure 8C
8 Document #05131A
MODEL A490TCF STROBE POWER SUPPLY
FAA/PMA APPROVED
Model Number . . . . . A490TCF
Part Number . . . . . . . 01-0770006-08
Operation Operation
MODEL A490TCF: This model operates one strobe lighthead. It is our MODEL A490TCCF SERIES: This model
most compact unit and can be mounted in the wingtip and/or the tail is the same as the A490TCF but has
adjacent to the lighthead. It produces a mounting plate with additional
an accumulated 19 joules of power. holes that directly replaces
It will only meet 400 ECP when factory installed systems
used with the A470A-W. This on single engine Cessna’s,
unit can not be synchronized. Aero Commanders and
This power supply operates Grumman Americans.
from 10 to 30 volts DC.
(Not approved for use with
red strobe light).
OUTPUT
C
L CABLE
C
L
INPUT CABLE
MOUNTING HOLES
2.38 Figure 9C
.187” DIA. (4) PLACES
C
L Mounting 5.000
3.250
Mounting 5.562”
.191 DIA.
(4) PLACES
.938”
Operation Dimensions
Equipment Limitations: The Model 70900 series LED anti-collision
light assembly meets the requirements of FAR 23.1401, 25.1401 and
91.205(c)(3). “If certification for night operations is requested, the 3.66”
airplane must have an anti-collision light system that consists of one
or more approved anti-collision lights located so that their light will
not impair the flight crew members vision or detract from the con-
spicuity of the position lights.”
Continued Airworthiness: The 70900 series LED anti-collision light
assembly is designed with 10 vertical columns consisting of 3 LEDs
each. Should any one LED or any vertical column fail, the unit must
be repaired or replaced.
Installation Procedures: The following information is to assist in the
installation of a Whelen LED Flashing Anti-collision Light System.
1. The installation procedure described in the following text will be
confined to a single light installation, but is identical for multiple
light installations.
2. Prepare the aircraft for means to secure the LED Flashing
Anti-collision Light assembly (see reference AC 43.13-2A, Ch. 4).
3. 14 and 28 VDC (+) and (-) ground leads equipped with an appro-
priate sized breaker to be supplied to the LED Flashing Anti-colli- 4.04”±.06
sion Light Assembly System. Both leads must be connected by
an approved FAA connection. Insure that the wire leads and the
pressure venting tube are all clear of any obstructions and ty-
wrap as required. The pressure venting tube may be trimmed to
minimum length of 1” from base.
4. Install the light assembly by securing to aircraft using #6-32 x
3/8” (maximum length) approved hardware. Note: Lens mount- (+)14VDC Red 18GA MFG Label
ing screws installed at 5-7 in./lbs. of torque. Teflon Wire 18” LG
or
5. Check all avionics systems for interference from this installation. (+)28VDC White 18GA
6. A flight check should be performed by a properly certified pilot. Teflon Wire 18” LG
7. All inverted (bottom) mounted units shall require waterproofing (-)Ground Black 18GA
of the unused mounting holes. An application of single-part sili- Teflon Wire 18”LG
cone (RTV) or equivalent applied into mounting holes is recom-
mended (see illustration on page 11, Fig.11A). Inverted and/or Teflon Tube 18GA
standard mounted units, when necessary, may require water- (Pressure Venting)
proofing around any open area where water could get in.
Specifically, the lens to the flasher base assembly, and the flash-
er base assembly to the aircraft.
8. Update aircraft records, complete Form 337 and obtain FAA field
approval for installation. If not covered under STC eligibility list. Figure 10A
10 Document #05131A
Figure 11A
Lens
P/N: 68-4990257-30
Screw
P/N: 14-062216-05M
Gasket
P/N: 38-0250843-00
LED Module
P/N (14V): 01-0270918-01
P/N (28V): 01-0270918-03
115°
115°
Figure 11B
4. Install the light assembly by first removing the lens. Remove the
adapter plate. Attach the adapter plate to the aircraft mounting holes.
Refer to page 2. Reinstall the light assembly and lens. MFG. Label
5. Check all avionics systems for interference from this installation.
6. A flight check should be performed by a properly certified pilot. (-)GROUND Black 18Ga.
Teflon Wire 12"±1"LG
7. All inverted (bottom) mounted units shall require waterproofing of
the flasher base assembly to the aircraft. Note: Drill a 1/8” hole in the
center of the lens for bottom mount units. (+)14VDC Red 18 Ga. or
(+)28VDC White 18 Ga.
8. Update aircraft records, complete Form 337 and obtain FAA field TEFLON WIRE 12"±1”LG
approval for installation. If not covered under STC eligibility list. Figure 12A
12 Document #05131A
Figure 13A
Screw (4-40 X 5/16 PPHMS) MS51957-14
P/N: 14-0050505-14
Lens Retainer
P/N: 19-171047-100
Lens
P/N: 68-4971046-30
Lens Gasket
P/N: 38-0250885-00
Adapter Plate
P/N: 07-771051-100
(-) GROUND Black 18 Ga. Suggested Mounting Hole Pattern
TEFLON WIRE 12”+1”LG
14 Document #05131A
Dimensions *NOTE* ALIGN REFLECTORS AS SHOWN
2.33” DIA. 1 2 3
4 5 6
OPTIONAL MOUNTING
ADAPTER POSITIONS
7
9
8
7.01” +/-.03
10 11
12
1.75”
Model HRCFA Parts List
16 19-130074-100 A440 MOUNTING FLANGE (OPTIONAL)
15 N/A #6 INT. TOOTH LW(MS35333-71)
14 N/A #6-32x3/8 PPHMS(MS51957-28)
13 01-0770619-00 POWER SUPPLY ASSEMBLY
3.67” DIA
12 01-0770044-02 A469B FLASH TUBE ASSY.
11 38-0250429-00 RFI GASKET
13
10 38-0230840-00 GASKET
Mounting .156” DIA.
14 15 9 N/A #6-32 X 5/16 SS HEX NUT (MS35649-264)
(5) HOLES
8 01-0450685-00 CLAMP RING
16
7 N/A #6-32x1/2 PPHMS(MS51957-30)
4 LENS, A402ADR
OL
68-2170504R50
DR I
E
D
IF
I NVE RT
BLACK(GROUND)
Figure 13A
WHITE(+14/28V)
Dimensions 1
6
SHOWN ROTATED FOR
8 2 ILLUSTRATION OF PARTS
5.50”
2.97”
1.75”
OPTIONAL 10 4
LOCATION
3.67” DIA.
18.00 ±1.00
WHITE (+)
The A450 and A470A remote anti-collision strobe lighthead assemblies Model A470A Installation
are direct replacement for the quartz-type flasher, using the orig-
inal or the H102 “B” mounting adapter.
The H102 “B” mounting adapter is mounted in the aircraft’s structure, Figure 14
with four (4) MS 20470 AD4 rivets, or four (4) 6-32 screws and self- H102 Mounting Adapter 8X ∅.136
.150
locking nuts. Drill out the center hole in the skin to allow access to the
strobe head connector.
∅1.00
∅2.485
∅1.625 ∅1.250
BOLT CIRCLE BOLT CIRCLE
16 Document #05131A
Vertical Fin and Rudder Mounting of Anti-Collision
Strobe Lights
Rudder mounted anti-collision lights should be located top center of
the rudder hinge center line, or rudder balance must be established
after installation. Refer to AC 43.13-2A, Chapter 4, Paragraph 55(e),
“Rudder Installation”. The rudder or fin cap is excellent for shadowing
the prop and cabin area if the light is mounted far enough back.
FIG. 15C FIG. 15D
Round or streamline tubing cut to fit Metal bracket shaped to fit the vertical fin or
rudder or vertical fin welded to 2 /12” OD rudder with 2 1/2” OD .040” thick disc riveted
.40” thick disc. (Reference AC 43.13-1B, in place. (Reference AC 43.13-1B, Chapter 2).
Chapter 2, Section 2).
Dimensions
- - - - - - 17 02-0350600-01 LENS ASSY, MASKED (WHITE)
1 1 1 1 1 1 15 N/A #6-32 X 5/16 SS HEX NUT (MS35649-264)
1 1 1 12 38-0230840-00 GASKET 1
1 1 1 1 1 11 N/A #6-32 X 1/2 PHILLIPS PHMS(MS51957-30) THRU
3.50”
1 1 1 1 1 1 10 01-0770044-02 FLASHTUBE ASSY (A469B) 6 17
1 1 1 9 38-0250429-00 GASKET, SHIELDED
1 1 1 1 1 1 8 01-0450685-00 CLAMP RING Ø.50
1 6 68-2170504R60 LENS ASSY, R S - (RED/WHITE)
8
1 5 68-2170504R30 LENS ASSY, R S - (WHITE)
1 4 68-2170504R50 LENS ASSY, R S - (RED) 15
1
2
3
1 3 68-2170504-60 LENS ASSY. (RED/WHITE) 9 12
WHITE
RED
BLACK
1 2 68-2170504-30 LENS ASSY, (WHITE)
1 1 68-2170504-50 LENS ASSY, (RED)
2.58” DIA 11
* 01-0770019-23 STROBE ASSY, R S - R/W (A470A-D-R/W)
10
A470A- * 01-0770019-22 STROBE ASSY, R S - WHITE (A470A-D-W)
* 01-0770019-21 STROBE ASSY, R S - RED (A470A-D-R)
* 01-0770019-20 STROBE ASSY. - RED/WHITE (A470A-R/W)
* 01-0770019-19 STROBE ASSY. - WHITE (A470A-W)
* 01-0770019-18 STROBE ASSY. - RED (A470A-R)
QTY ITEM PART NUMBER DESCRIPTION
Figure 15A
6
1 6 N/A #6-32 X 5/16 SS HEX NUT (MS35649-264)
2.15” * 3 1
01-0770032-00 A450 STROBE LIGHT HEAD ASSEMBLY
A450
Figure 15B
Mounting
1. If necessary, fabricate the mounting pattern using dimensions
found in Figure 16B (Note - A 1” diameter hole is needed for the
connector to pass through). 2.47”
2. Make the necessary wiring connections using 18 gauge wire for the
position lights, and Whelen 16 gauge 3/c cable for the strobe lights.
All connections must use FAA approved techniques.
1.08” .15”
3. Remove the (6-32 x .312) retainer mounting screw and retainer.
4. Attach the base assembly to the wingtip using (3) #6-32 counter-
sunk screws (unit may be sealed around periphery with RTV or
equivalent).
1.35”
5. Re-attach lens retainer.
1.79”
Wiring
1. The strobe connector should plug into the Whelen 16 gauge inter-
connecting cable, or a Whelen strobe power supply. Pin 1 = RED (Anode)
Pin 2 = BLACK (Cathode)
Pin 3 = WHITE (Trigger)
Observe the following strobe color coding:
PIN 1 - RED (Anode)
PIN 2 - BLACK (Cathode)
PIN 3 - WHITE (Trigger) RED - (+14/28 VDC)
BLACK - (-)GROUND
Caution: When pins 1 & 2 or pins 2 & 3 are reversed, the system will
appear to operate normally, however this condition will cause pre- Figure 16A
mature flash tube failure.
2. Connect the forward position light wires as follows, using 18 gauge Mounting Diagram
approved aviation wire or cable: BOTTOM VIEW
RED - +14 or +28 volts (depending on aircraft voltage) .85”
BLACK - ( - ) Ground .88” 1.75”
.50”
1.00”
Figure 16B
18 Document #05131A
Figure 17A
10
11
1 12
Replacement Parts
14 02-0250276-03 FLASH TUBE ASSEMBLY (MOLEX CONNECTOR)
13 02-0250276-00 FLASH TUBE ASSEMBLY (A610)
12 68-2290005-30 LENS, FLASHTUBE (A612)
11 19-170052-009 RETAINER, LENS (A626)
10 N/A #6-32 X 5/16 PHILLIPS FHMS(MS51959-27)
8 02-0350003-01 BASE PLATE ASSEMBLY (W1285-2)
7 38-0130106-00 GASKET, FLASHTUBE, (A427-3)
6 38-0230021-00 GASKET, LENS (W1283)
5 34-0414020-65 LAMP, 14V (W129014)
4 34-0428020-65 LAMP, 28V (W1290-28)
3 68-4230020-40 LENS, GREEN (W1284G)
2 68-4230020-50 LENS, RED (W1284R)
1 02-0350072-35 LENS, CLEAR (A626D)
68-2290005-34 LENS, RFI COATED
A612
MODEL A612
Model Number Part Number Description
A612 . . . . . . . . . . . .68-2290005-30 . . . . . . . . . . . . . . . . . . . . . . . . .standard clear lens
A612D . . . . . . . . . .68-2290005-34 . . . . . . . . . . . . . . . . . . . .radio shielded, clear lens
Specifications
A612 Lens Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.08 lbs.
A610
Operation
The Model A610 flash tube and the Model A612 glass lens are used for installing wingtip 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. The unique magnifying design
of the A612 lens increases the light intensity by two to three times in the horizontal plane. Lenses meet material requirements of MIL-C-7989B
class B.
A610 Dimensions Late Model Single Engine Cessna Wingtip Strobe Light
Installation of A610 and A612
BEFORE
Before
CONNECTOR WIRING
POS 1 - RED (ANODE)
AFTER
POS 2 - BLACK (CATHODE)
POS 3 - WHITE (TRIGGER)
1.60”
(APPROX)
After
1. Remove the position light lens retainer being careful not to drop the
red or the green lens.
2. Establish a center line on the Cessna lens retainer, referencing to
the lens retainer center mounting screw, and position light base
plate rear mounting screw.
Figure 18A Figure 18C
CENTERLINE
A612 Dimensions
File to fit
1.682” 1.170” A612 lens
profile
1.68”
1.28” 3. Scribe the A612 lens profile as shown in illustration above, the
.125” WALL MIN. INSIDE
HEIGHT
object being to have the strobe light centered over the position light
base plate.
.240” 4. Trim or fit an opening to the scribe line to fit the A612 lens. Due to
the uneven surface of the Cessna lens retainer, the A612 will con-
1.75” tact only the front and rear radius.
1.00” RAD
5. Place the sponge rubber pad supplied under the A610 flash tube to
firm the assembly. RTV is recommended to secure lens in the mod-
ified retainer.
.375” RAD
6. The flash tube interconnecting cable is routed through square holes
in the rear bulkhead of the position light area.
7. Install the modified position light lens retainer, A610 flash tube and
Figure 18B A612 lens, using original hardware.
20 Document #05131A
MODEL A625 SERIES INSTALLATION
FAA/PMA APPROVED
Model Number Part Number Description
A625 . . . . . . . . . . . .01-0770058-03 . . . . . . . . . . . . . . . . . . . . .standard unit, clear lens
A625D . . . . . . . . . .01-0770058-13 . . . . . . . . . . . . . . . . . . . .radio shielded, clear lens
Specifications
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 lbs.
Exposed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7”
3 8
1 4
Figure 19A
Spare Parts
1 - 8 68-2290005-34 LENS, RFI COATED
2 2 6 N/A #4-40 HEX NUT, BRASS
1 1 5 02-0370338-00 A627 FLASHTUBE ASSY.
1 1 4 38-0250074-00 GASKET,
-
Bend and trim the adapter plate as necessary, so that the A625 clears
1 3 68-2290005-30 LENS, CLEAR
the transparent window that covers the navigation light area 0.060
- 1 2 19-170057-009 RETAINER, LENS
inch minimum.
2 2 1 N/A #4-40 X 1/2 PPHMS (MS51957-17)
The conduit for the navigation light wire is very small. To get the nec-
essary wires to operate the strobe light and the navigation light
* 01-0770058-13 STROBE LIGHT ASSY. MODEL A625D
through this conduit, use a 20 gauge wire, with less that 0.060 inch
* 01-0770058-03 STROBE LIGHT ASSY. MODEL A625
OD. It has been found that the Belden 8502 or 8308, has an 0.058
QTY. ITEM PART NUMBER DESCRIPTION
inch OD.
1.71”
1.75"
.19”
22 Document #05131A
A500A Spare Parts A500A-V-D-14
A500A-V-D-28
A500A-H-D-14
1 A500A-H-D-28
A500A-V-D-M-14
A500A-V-D-M-28
A500A-H-D-M-14
2 3 A500A-H-D-M-28 1
15
4
2 3
5
5
7 6 7
8
8
12 17
J2
A500A-V-14
A500A-V-28
A500A-H-14 J2 CONNECTOR WIRING J1 CONNECTOR WIRING
POS 1 - RED(ANODE) POS 1 - BLUE(+)
A500A-H-28 POS 2 - BLACK(CATHODE) POS 2 - BLUE(-)GROUND
POS 3 - WHITE(TRIGGER)
Figure 21A
1 1 1 1 1 1 1 1 32 46-0750698-00 PIGTAIL
- - - - - - - - 19 02-0350375-01 FLASH TUBE AND SOCKET ASSY (A506DM)
1 1 1 1 15 68-4270002-34 LENS, RFI COATED
1 1 1 1 14 02-0350375-00 FLASH TUBE AND SOCKET ASSY (A506D)
1 1 1 1 12 02-0350034-00 FLASH TUBE AND SOCKET ASSY (A506)
2 2 2 2 2 2 2 2 8 • = N/A HEX NUT,#4-40 X 1/4 A.F. BRASS
1 1 1 1 7 34-0428070-64 LAMP,ESG HALOGEN (28 VOLT) (A508-28)
1 1 1 1 6 34-0412070-63 LAMP,ERC HALOGEN (14 VOLT) (A508-14)
1 1 1 1 1 1 1 1 5 38-0230002-00 GASKET (A455)
1 1 1 1 4 68-4270002-30 CLEAR GLASS PLAIN DOME (A457A)
- - - - - - 1 1 3 19-0150350-02 RETAINER,MASK(VERTICAL)
- - - - 1 1 - - 2 19-0150350-01 RETAINER,MASK(HORIZONTAL)
2 2 2 2 2 2 2 2 1 • = N/A #4-40 X 1/2 PHILLIPS PHMS(MS51957-17)
Operation Wiring
Wingtip anti-collision, forward position, and tail position lights, 1. The strobe connector should plug into the Whelen interconnecting
all in one compact unit. Tail position light eliminates the need for cable, or a Whelen strobe power supply.
a tail mounted position light. Available in 14 or 28 volts, and in a
radio-shielded version. The forward position lamp is 26 watts and Observe the following strobe color coding:
the taillight lamp is 25 watts. PIN 1 - RED (Anode)
PIN 2 - BLACK (Cathode)
PIN 3 - WHITE (Trigger)
Installation Caution: When pins 1 & 2 or pins 2 & 3 are reversed, the system
The A600 Series must be properly mounted to comply with FAR Part will appear to operate normally, however this condition will cause
91.205(c-2) & (c-3). The light assembly must be mounted so that the pre-mature flash tube failure.
light distribution pattern is not obstructed by any parts of the aircraft. 2. Connect the forward position light wires as follows:
A limited amount of obstruction is permitted (Ref. FAR Part 23.1401 for
anti-collision lights, and PAR 23.1387 for position lights). RED - +14 or +28 volts (depending on aircraft voltage)
The convergence of the two wingtip tail position must occur within BLACK - ( - ) Ground
1200 feet directly behind the aircraft to comply with field of coverage 3. The tail position light has no polarity, as noted by both wires being
requirements. The baseplate must be mounted parallel to the vertical & BLUE. Connect one BLUE wire to +14 or +28 volts (depending on
horizontal centerlines of the aircraft to project the patterns properly. aircraft voltage). Connect the other BLUE wire to ground (see fig-
ure 22B)
Dimensions
Mounting 5.63”
1. If necessary, fabricate the mounting pattern using dimensions
found in figure 22A.
1.83”
2. Make the necessary wiring connections using 18 gauge wire for the
position lights, and Whelen 16 gauge 3/c cable for the strobe lights.
All connections must use FAA approved techniques.
1.66”
3. Remove the two (6-32 x .312) retainer mounting screws and
retainer.
4. Attach the base assembly to the wingtip using (3) #6-32 counter- 2.46”
sunk screws (unit may be sealed around periphery with RTV or 110°
equivalent). 70°
5. Re-attach lens retainer (see figure 23A). .15”
1.08”
1.00”
.50” POS 3 - WHITE(TRIGGER)
POS 2 - BLACK(CATHODE)
POS 1 - RED(ANODE)
RED (+14 or +28VDC)
.88” BLACK (-) GROUND
1.35”
1.75” DIA. 18 AWG TEFLON
LEAD LENGTH 6.00"±1.00"
24 Document #05131A
A600 Replacement Parts
9
18 68-2290005-30 LENS, CLEAR(A612)
17 38-0130107-00 GASKET(A427-4)
16 68-2290005-34 LENS, RFI COATED
14 38-0130090-00 GASKET(A616)
7
13 38-0230021-00 GASKET(W1283)
12 68-4250066-30 LENS, TAIL POSITION(A615)
11 34-0428070-64 LAMP, 28V(A508-28)
10 34-0412070-63 LAMP, 14V(A508-14)
9 N/A #6-32 X 5/16 PHILLIPS FHMS (MS51959-27)
18 16
8 02-0350260-00 SOCKET ASSY.(A507)
7 19-170049-009 LENS RETAINER(A606)
6 68-4230020-50 LENS, RED(W1284-R)
5 68-4230020-40 LENS, GREEN(W1284-G)
4 34-0428020-65 LAMP, 28V(W1290-28)
3 34-0414020-65 LAMP, 14V(W1290-14)
2 2 02-0250276-00 FLASH TUBE ASSEMBLY(A610)
1 02-0350259-00 BASEPLATE ASSY.(A605)
17
5 6 ITEM PART NUMBER DESCRIPTION
12
14
13
8
3 4 10 11
Figure 23A
CONNECTOR WIRING
POS 1 - RED(ANODE)
Before POS 2 - BLACK(CATHODE)
Figure 24B POS 3 - WHITE(TRIGGER)
26 Document #05131A
STROBE POWER SUPPLY CROSS REFERENCE REPLACEMENT LISTING
Old Part Number Old Model Number Description Current Replacement
A413,HS-41-14 HS,41 Single strobe unit, SingleFlash, 14 VDC, 33 joule
A413,HS-41-28 HS,41 Single strobe unit, SingleFlash, 28 VDC, 33 joule
A413,HD-14 HD Dual strobe unit, SingleFlash, 14 VDC, alternating
A413,HD-28 HD Dual strobe unit, SingleFlash, 28 VDC, alternating
A413,HD-42-14 HD,42 Dual strobe unit, SingleFlash, 14 VDC, alternating 33 joule
A413,HD-42-28 HD,42 Dual strobe unit, SingleFlash, 28 VDC, alternating 33 joule
A413,T2-14 HD,T2 Dual strobe unit, SingleFlash, 14 VDC, simultaneous, 16 joule
A413,T2-28 HD,T2 Dual strobe unit, SingleFlash, 28 VDC, simultaneous, 16 joule
A413,T2-DF-14 HD,T2,DF Dual strobe unit, DoubleFlash, 14 VDC, simultaneous, 16 joule
A413,T2-DF-28 HD,T2,DF Dual strobe unit, DoubleFlash, 28 VDC, simultaneous, 16 joule Model HDACF
A413,T3-14 HD,T3 3 strobe unit, SingleFlash, 14 VDC, w/trigger function P/N 01-0770028-05
A413,T3-28 HD,T3 3 strobe unit, SingleFlash, 28 VDC, w/trigger function
A413,HD,DF-14 HD,DF 3 strobe unit, DoubleFlash, 14 VDC
A413,HD,DF-28 HD,DF 3 strobe unit, DoubleFlash, 28 VDC
A413,T3-DF-14 HD,T3,DF 3 strobe unit, DoubleFlash, 14 VDC, w/trigger function
A413,T3-DF-28 HD,T3,DF 3 strobe unit, DoubleFlash, 28 VDC, w/trigger function
A413A,HDA-DF-14 HDA,DF-14 4 strobe unit, DoubleFlash, 14 VDC
A413A,HDA-DF-28 HDA,DF-28 4 strobe unit, DoubleFlash, 28 VDC
A413A,HDA-DF-14/28 HDA,DF-14/28 4 strobe unit, DoubleFlash, 14 or 28 VDC
A413A,HDA-CF-14/28 HDA,CF-14/28 4 strobe unit, CometFlash®, 14 or 28 VDC
Inspect Lens
Excessive
scratches, Yes
Replace Lens
discolorations
or cracking?
No
Check Lens
Mounting
No
Check
Operation
Improper Yes
Check wiring
Operation? and connections
Refer to
trouble-shooting
procedures for
No
strobe lights
Complete
28 Document #05131A
STROBE SYSTEM TROUBLE-SHOOTING
TROUBLE-SHOOTING PROCEDURES FOR AVIATION CABLE CONTINUITY CHECK PROCEDURES
ANTI-COLLISION STROBE LIGHT SYSTEMS If pins 1 and 3 are reversed, or if there is a short between pins 1 and 2
WHEN REPAIRING WHELEN ANTI-COLLISION STROBE LIGHT SYS- of the interconnecting cable, the power supply will be rendered non-
TEMS, USE ONLY WHELEN FAA APPROVED HARDWARE. BE CAREFUL operable until the short is cleared. A short of this type will not cause
OF STROBE LIGHT PARTS THAT ARE SIMILAR IN APPEARANCE! any permanent damage to the power supply. However a discharge of
the condenser across pin 1 and pin 3 will destroy the trigger circuit in
The Whelen Aviation Strobe Light is a condenser discharge strobe light the power supply.
system. A condenser is charged to approximately 450 volts DC, then
discharged across a xenon flash tube at controlled intervals. The con- 1. Check for continuity between the connectors of each interconnect-
denser is parallel across the xenon flash tube that is designed to hold ing cable:
off the 450 volts DC applied, until the flash tube is triggered by an Pin 1 to pin 1 (red wire = anode +).
external pulse. This pulse is generated by a solid-state timing circuit in
the power supply. Pin 2 to pin 2 (black wire = flash tube ground -).
When trouble-shooting a strobe light system, first determine if the Pin 3 to pin 3 (white wire = trigger).
trouble is with the flash tube or the power supply. This can be accom- 2. Check for shorts between pins 1 and 2, pins 1 and 3, and pins 2
plished by replacing the flash tube assembly with a good operating and 3 of the interconnecting cable.
flash tube, or with the use of a Whelen Strobe Check unit.
NOTE: When pins 1 and 2, or pins 2 and 3 are reversed, the system will
Whelen’s power supplies are protected against a short or open circuit appear to operate normally, but these conditions will cause early flash
on the output. In either case, the power supplies will effectively turn tube failure, and void the flash tube warranty.
themselves off when subjected to a shorted output of a xenon flash
tube that refuses to flash.
WARNING: Strobe light power supplies are meant to be used, not to
remain in an inactive state. Use them at all times, this will improve their XENON FLASH TUBE PROCEDURES
proper functioning. Any strobe light power supply that has been out of 1. A xenon flash tube can be very photosensitive. One will flash nor-
service for a long period of time is subject to failure because the elec- mally when exposed to an external light source, but may become
trolytic condenser loses the polarity formation. A strobe light power hard to fire when subjected to darkness.
supply not having been used for one year or longer is vulnerable to
failure, applies to 1993 & older units. 2. They will become hard firing with age, or when exposed to a very
high temperature. A hard firing tube will sometimes operate with
If this is the case, it is recommended to start operating the system on the engine running, but will fail when operated on a low battery.
a voltage that is reduced by 25 percent for 10 to 15 minutes before put-
ting the power supply into normal service. This will prevent overheat- 3. They can develop a leak through eggshelling of the glass, or a leak
ing of the condenser while they reform. If the power supply, after a long can develop around the seal of the wire to the glass. This is caused
period of non use, is operated at full voltage immediately, there is an by hot and cold cycling of normal operating of the system.
excellent possibility that the condenser will become overheated. 4. They can go into self-ionization (continuously glow a light blue),
thus rendering the entire system non-operational until flash tube is
replaced. This most likely occurs when the input voltage is highest.
POWER SUPPLY TEST PROCEDURES This can be checked by turning the system off. When turning the
system back on, it generally will operate normally for a few flashes
THE POWER SUPPLY IS A HIGH VOLTAGE DEVICE. LET THE before going back into self-ionization.
POWER SUPPLY BLEED DOWN FOR 10 MINUTES AFTER ANY OF THE ABOVE MENTIONED CONDITIONS ARE REASONS FOR
TURNING OFF POWER BEFORE HANDLING. REPLACEMENT OF THE XENON FLASH TUBE.
WARNING: Reverse polarity of the input power, for just an NOTE: Installing one new flash tube in any multi-head strobe light sys-
instant, will permanently damage the power supply. This dam- tem, will sometimes cause the remaining old flash tube to misfire or
age is sometimes not immediately apparent, but will cause fail- skip. This signifies that the old flash tube is nearing the end of it’s serv-
ice life. However, to check the questionable flash tube, install it in a sys-
ure later on. tem and apply a reduced voltage, approximately 20 percent, to the
External trigger switching is not provided on the A413A, HDA- input to the power supply. If the flash tube will operate at this reduced
DF Strobe Light Power Supply (Reference A413,T3-DF old style level, it still has a great deal of service life in it.
strobe light power supply, outlet #1). Do not short out high volt-
age for extended length of time; it will cause overheating of the
output diodes and cause possible failure. WHELEN’S (CometFlash® “CF” Strobe Light System)
consists of four high energy pulses per burst of light, 45
bursts of light per light.
A normal operating power supply emits an audible tone. If there is no
sound emitted, investigate.
NOTE: Whelen Engineering does not recommend attempting to repair
1. Determine that there is a proper input voltage at the power supply. their strobe light power supplies in the field. It is recommended to take
If this test is positive go to step 2. advantage of our 48-hour Repair Service.
2. Clear all possible shorts at the power supply, by disconnecting the
output cables from the power supply outlets, and connect an oper-
ating strobe lighthead assembly or a Strobe Check unit directly to
the power supply outlet, then apply the required voltage to the
power supply input. If this application proves positive the power
supply is in working condition, and the problem may be with the
interconnecting cables.
30 Document #05131A
PARTS BREAKDOWN - AIRCRAFT STROBE BEACONS
Model Number Part Number Description Model Number Part Number Description
5068500 01-0450685-00 Clamp Ring Assy. A626D 02-0350072-35 Lens/Retainer Assy. for A650 Series,
Radio Shielded
A402AR 68-2170504-50 Optic Lens, Red
H102 07-730068-000 Mounting Adapter for A470A Series
A402AS 68-2170504-60 Optic Lens, Split, Red/White
H103 11-230079-000 Mounting Adapter for A470A Series
A402AW 68-2170504-30 Optic Lens, White
3-3/4 dia mounting pattern
A424 11-430005-100 Taillight, Mounting Cup
SA402 68-4230044-30 Lens, Clear for SACF & A450 Series
A425 19-130000-100 Taillight, Lens Retainer
SA406 02-0350053-00 Strobe Tube for SACF & A450 Series
A425AH 19-0150350-01 Retainer, Horizontal Mount
SA4181 38-0230104-00 Gasket for SA402 Lens
A425AV 19-0150350-02 Retainer, Vertical Mount
W1282 19-150002-009 Lens Retainer for W1285 Series
A426 19-190000-009 Retainer for A428 Lens
W1283 38-0230021-00 Gasket for W1284 Lens
A427 02-0250274-00 Strobe Tube Assy.
W1284G 68-4230020-40 Position Light Lens, Green
A427-4 38-0130107-00 Gasket/Spacer for A428 Lens
W1284R 68-4230020-50 Position Light Lens, Red
A428 68-4290001-30 Lens
W12852 02-0350003-01 Base Plate Assy.
A428C 02-0350033-00 Lens, Radio Shielded
W129014 34-0414020-65 Position Light Lamp, 14V
A428D 02-0350057-00 Lens/Retainer Assy Radio Shielded
W129028 34-0428020-65 Position Light Lamp, 28V
A435 02-0350054-00 Strobe Tube Assy, A430 Series
A440 19-130074-009 Mounting Adapter Ring
A441 01-0430011-00 Kit, 3 Pin Connector & contacts
A442 01-0410823-00 Kit, 3 Socket Connector & contacts
A443 02-0230081-00 Trigger Jumper Plug for HDACF
A444 02-0230007-00 Kit, 2 Pin Connector & contacts
A446 02-0230085-00 Kit, 2 Socket Connector & contacts
A455 38-0230002-00 Gasket, A457A Lens
A457A 68-4270002-30 Lens
A457AD 02-0350038-35 Lens, Shielded
A457BDH 02-0350038-37 Lens/Retainer Assy, Radio Shielded,
Vertical Mounting
A457BDV 02-0350038-36 Lens/Retainer Assy, Radio Shielded,
Horizontal Mounting
A469A 01-0770044-00 Strobe Tube Assy.(non reflective base)
A469B 01-0770044-02 Strobe Tube Assy.
A469D 01-0770044-01 Radio Shielded Strobe Tube Assy.
A469DK 01-0710834-00 Radio Shielding Kit for A469A
A504 06-150058-001 Disc, Lamp Socket for A555A Series
A506 02-0350034-00 Strobe Tube/Socket Assy. For A500A
A507 02-0350260-00 Lamp Socket for A555A Series
A50814 34-0412070-63 Halogen Lamp 14V 25 Watt
A50828 34-0428070-64 Halogen Lamp 28V 25 Watt
A605 02-0350259-00 Base Plate Assy. For A600 Series
A606 19-170049-009 Retainer for A600 Series
A610 02-0250276-00 Strobe Tube
A612 68-2290005-30 Magnifying Lens for A610
A612D 02-0350071-35 Lens/Retainer Assy. Radio Shielded
used on A600 Series
A615 68-4250066-30 Taillight Lens used on A600 Series
A616 38-0130090-00 Gasket for A615 Taillight Lens
A626 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.
A628
A425 A425A
A425A
A402A- ( )
A455 01-0450685-00
A455
A455 01-0450685-00
A629
A508
A508
A435 A507
SA418-2
A506
A627
A467
A504
A441 SA406
A424
A469B
A430 A441 A444
A441
A500A
A625 A441 A441
A444
IMPORTANT NOTE: A450 A470A
When ordering models A500A and A555A,
or lens assembly part number A457B-D, A555A
make sure to SPECIFY HORIZONTAL
OR VERTICAL.
W1282
A626 A626
A606
W1284
W1284
A612 A612 A612
W1283
W1283
W1283 A610 A610
A610
W1290 W1290
W1290
A507
A427-3 A427-3
A427-4
A508
A616
A605 W1285-2
W1285-2
A441 A441
A441
A615
A600-PR A650-PR A650 W1285-PR
A600-PG A650-PG W1285-PG
32 Document #05131A
APPENDIX A
50 Document #05131A
®