CALI alumLEDs ALS500T-SWM-FG User manual
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 1 of 20
Overview
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
IMPORTANT NOTICE: VERIFY CORRECT LUMINAIRE WAS RECEIVED WITH
CORRECT COLOR TEMPERATURE, VOLTAGE, AND WATTAGE BEFORE CUTTING OR
INSTALLING. CALI WILL NOT BE RESPONSIBLE IF INCORRECT LUMINAIRE IS INSTALLED.
READ ENTIRE GUIDE BEFORE STARTING INSTALLATION
• Indirect lighting
• 24 Volts DC for easy and safe installation
• Long life, energy efficient LEDs
• Available in 4 Watts up to 12 Watts Per Foot
• Can be ordered to specific lengths for when exact dimensions are known
Example: 10 x 10’6” (product is shipped in 8’ max luminaires)
• Available for indoor (DRY) and (DAMP) rated installations
PRODUCT INFORMATION
• Electric Hammer Drills (optional)
• 14.4 to 28 Volt Cordless Drills
• Phillips Bits - Sufficient Quantity
• Utility Knife
• Electrical Cords
• Marker
• Wire Strippers
• Long Nose Pliers
• Drill Bits - Concrete or Wood
• Electrical Three Ways
• Safety Glasses
• Measuring Tapes
• Chalk Line
• ALS500T-SWM can be mounted to concrete, wood, or metal using proper
mounting hardware.
• Ensure surface material can support the weight of the luminaire.
ELECTRICAL
INSTALLATION RECOMMENDATIONS
INSTALLATION TOOL REQUIRED
• ALS500T-SWM requires a remote driver. The driver may be mounted on
top of the luminaire or in a remote location.
• Drivers are 120V - 277V (UNV) Input Voltage and 24VDC Output Voltage
• To calculate driver size, determine Watts per Foot.
Example: 4W per Foot
• Determine Length in Feet.
Example: 20’
• To calculate Load, Multiply Watts per Foot x Length in Feet
Example: 4W x 20’= 80W. The Load of the driver is 80 Watts.
• Maximum load for a Class 2 low voltage luminaire is 96 Watts
FEATURES
APPLICATIONS Indirect Lighting
LENS Clear
LENGTH Built to Order (± 0.25” Tolerance)
CONSTRUCTION Aluminum Extrusion
FINISH White Powder Coated
DRIVER Remote
WEIGHT 4.15 lbs per foot
MOUNTING Mounting Brackets or Aircraft Cable
LISTING
Dry or Damp Location
UL1598, CSA C22.2#250.0
UL8750, CSA250
UL2108, CSA C22.2 #9
TEMPERATURE
RATINGS
Operating / Startup: -20° to 48°C (-4° to 120°F)
Storage: -40° to 76°C (-40° to 170°F)
END VIEWS (With Flange Ceiling Trim)
4.0”
1.37”
1.59”
3.75”
Max.
7.0”
4.21”
Hanging Bracket Assembly
(ALS500T-SWM-HB)
4.0”
1.59”.60”
1.45”
4.21”
Wall Trim &Mounting Bracket Assembly
(ALS500T-SWM-WT)
(ALS500T-SWM-MB)
4.0”
1.37”
1.59”.60”
X (Specified Length)
4.21”
Aircraft Cable Assembly
(ALS500T-SWM-AC)
CONTENTS
CARE & MAINTENANCE Page 2
DESIGN GUIDELINES Page 3
WALL TRIM & MOUNTING BRACKET Page 4 - 6
HANGING BRACKET MOUNTING Page 7 - 9
AIRCRAFT CABLE MOUNTING Page 10 - 13
REFLECTIVE FILM Page 19
TROUBLESHOOTING Page 20
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 2 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Product Care & Maintenance
CLEANING MATERIALS
The use of solvents and/or cleaners which are not compatible with polycarbonate will result in
the softening, crazing, and/or cracking of the plastic part. This is especially true of polycarbonate
lamps and mounting bases which may be under stress in their normal applications.
COMPATIBLE WITH POLYCARBONATE
FIGURES
NOT COMPATIBLE WITH POLYCARBONATE
• Mild soap and water
• Mineral Spirits
• Isobutyl alcohol
• VM and P Naphtha
• Varsol No.2
• Mexane
• Freone TF and TE-35
• Ethanol
• Dirtex
• 2% Sol. Reg. Joy
• 10% Sol Bon Ami
• White Kerosene
• Methyl alcohol
• Heptane
• Petroleum Ether/65 degrees C
• Isopropyl alcohol
• Lacryl PCL-2035 polycarbonate cleaner
• Trichlor
• Gasoline
• Liquid Detergents
• Acetone
• Carbon Tetrachloride
• Pink Lux (Phosphate free)
• Triclene
• Chlorinated Hydrocarbons
•#1 & #3 denatured alcohol
• Methyl Ethyl Keytone (MEK)
• Texize-8006, 8129, 8758
• MIBK
• Liquid Cleaner – 8211
• Toluol
• Agitene
• Benzol
• Ajax
• Kleenol Plastics
• Lysol
• Stanisol Naphtha
• Oils
• Lemon Joy (phosphate free)
• Diversol
• Lestoil
WARNING
When using alumLEDs for any application, basic safety precautions should always be
followed to reduce the risk of fire, electric shock, and personal injuries.
AlumLEDs must be installed in accordance with the NEC or CEC as applicable.
CALI will not be responsible for any damage or malfunction caused by the following:
• Ensure power is off before installation begins, during replacements, additions, or repairs.
• Do not use alumLEDs if damaged, such as broken boards, loose connections, or frayed
wire insulation. Inspect before installing.
• Do not install alumLEDs in hazardous locations.
• Do not cover alumLEDs with any material. Covering may cause LEDs to overheat, melt, or ignite.
• Do not paint on or over fixture lens or LEDs.
Paint or any other substance on lens or LEDs will cause a shift in color temperature.
• Soffit must be evenly painted with a neutral white to avoid color shift.
• Do not modify alumLEDs in the field.
• Do not overlap alumLEDs luminaires in any way.
(Fig. 1)
• alumLEDs have line voltage risk of shock. Consult factory for any malfunctions.
Do not attempt to repair.
• Only use alumLEDs with specified rated voltages. Do not exceed the specified voltage for
any alumLEDs luminaire.
• Do not use alumLEDs extrusion as a raceway for additional wire. Non-factory feed
through wires inside alumLEDs will void warranty.
• Ground Fault Circuit Interrupter (GFCI) protections should be provided on circuits or
outlets when alumLEDs is used for outdoor applications.
• Surge protector must be set up for electrical power system to avoid damaging alumLEDs
lighting system.
• Do not connect wires together, follow provided wiring diagrams.
• Do not cut wire while energized.
(Fig. 2)
• Do not exceed maximum run lengths.
• Do not secure alumLEDs with nails or like means that might damage the wiring inside.
Only secure by using mounting clips.
• Do not mount alumLEDs inside tanks or enclosures of any kind.
• Do not install downward facing luminaires without set screws.
• Do not use improper screw head type on mounting clips. It will cause the mounting clip to
open up and become dysfunctional.
• Do not modify mounting clips.
• Do not mount fixture with less than the minimum number of mounting clips required.
See mounting clips section for details.
• Do not force alumLEDs into a space that is too small.
• Do not force alumLEDs with cord grip into soffit.
(Fig. 3)
• Do not install alumLEDs at an angle within a cove.
Only install fixtures straight within a cove.
(Fig. 4)
• Do not bend extrusion around radius.
• Do not submerge dry or wet location alumLEDs in any liquid.
• Do not install wet location in outdoor coves without proper drainage.
(Fig. 5)
• Do not install alumLEDs in any area that is continuously exposed to flowing or pooling
water, such as underneath drain pipes, sprinklers, fountains, misters, etc.
• Do not cut, puncture, or penetrate alumLEDs aluminum housing, end caps, or lens covers.
• Do not drop, bang, or rest weight upon alumLEDs.
• Do not apply excessive pressure to any part of alumLEDs.
• Do not remove end caps from alumLEDs.
• Do not bend alumLEDs power cord or continuous connector past permitted bend radius.
Bending past permitted bend radius will break the seal of the cordgrip or damage the
insulation.
(Fig. 6)
Wet Location: 3.5” minimum bend radius
Dry Location: 1.5” minimum bend radius
• Do not install alumLEDs in places where the power cord is subject to continuous flexing.
• Do not twist continuous connector or power cord.
• Do not hold, carry, or suspend alumLEDs by the power cord.
• Do not install alumLEDs on ceilings without mounting clips and set screws.
(Fig. 7)
Fig. 1 Fig. 2 Fig. 3
Fig. 4 Fig. 5
Fig. 6
Mounting Clip
Set Screw
Fig. 7
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 3 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Design Guidelines (Configurations)
LINEAR CONFIGURATION
8’ 8’ 3’6”
19’6”
End Cap
C
Standard LengthACustom LengthB
MITERED CONFIGURATION
8’ 1’
1’
6’
8’
Standard LengthA
Custom LengthB
Mitered CornerD
Mitered CornerD
End Cap
C
JUMPER CONFIGURATION
8’ 8’
Jumper CableE
Standard LengthAEnd CapC
POWER DISTRIBUTION
Continuous ConnectionG
DriverF
DriverF
To Power Source
To Power Source Circuit #2H
(White)
Circuit #1H
(Gray)
KEY
AStandard Length: Luminaire runs are constructed in 8’ segments.
BCustom Length: Any required length that is not 8’. Typically the last
segment of a run.
CEnd Cap: Used to terminate a run.
DMitered Corner: Standard 90° Mitered Corner. Custom angles available
upon request.
EJumper Cable: Used to connect two luminaires with a gap between.
F
Driver: The driver is typically mounted on top of the first luminaire
segment of a run. The driver may also be mounted elsewhere. Each run
typically has its own driver.
GContinuous Connection: Each luminaire segment is built with quick
disconnects to easily connect to the next segment in line.
H
Circuits: Example U-Shaped run exceeds Max Run lengths and is split
into two circuits, each with their own driver. Max Run lengths vary by light
source. See light source specifications for details.
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 4 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Diagram of Assembly (Wall Trim & Mounting Bracket Assembly)
5/8” Drywall
1/8” Mud
Wall Stud
Wall Trim
Lens
Trim Retention Spring
Flange Ceiling Trim Ceiling Tile
Tie Wire
Flange
Connector Block
Reflective Film
Mounting Bracket
DIAGRAM OF ASSEMBLY
4.81”
.06”
1.34”
4.0”
5.45”
1.37”
DIMENSIONS
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 5 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Mounting (Wall Trim & Mounting Bracket Assembly) 1 of 2
Mount Wall Trim
Ceiling Line
6-1/8”
5/8” Drywall
T-Bar
Support WireWall Stud
Maintain
Continuous Edge
Hang luminaire
on Wall Trim
Hold in place
Ceiling Line
4”
5/16”
Hex Nut
Lock Washer
Hex Head Bolt
Slide Mounting Brackets
onto Luminaire
Each Mounting Bracket secures
the luminaire to the Wall Trim
Do not install ceiling tiles until after installation of luminaires is complete.
Installation area must have at least 10” of overhead space.
1Determine number of Mounting Brackets required.
Note: Refer to the diagrams on page 16 as a guide.
5
If applicable, assemble Mounting Brackets. Insert Hex Head Bolts through holes,
then place Lock Washer and Hex Nut on bolts. Leave the assembly loose for now.
6
Hang luminaire from mounted Wall Trim and hold in place. Have another person
slide Mounting Brackets onto luminaire and Wall Trim. Tighten bracket nuts
slightly so the bracket securely holds the luminaire in place. Do not tighten nuts
completely at this time.
7
Install T-Bar ceiling grid. Assemble the grid so there is a continuous edge
around grid for the Ceiling Trim to rest on. Hang the center of the T-Bar 6-1/8”
away from wall stud.
2
Mark locations along Wall Trim extrusion where it will be mounted to wall studs,
then drill holes as needed and mount to wall studs.
Note: Mount Wall Trim extrusion using at least 1 screw per 2’, rounded up.
4
Hang or cut drywall along installation area so it is exactly 4” above ceiling line.
Note: Drywallers must hang drywall to the specifications. Only cut if necessary.
3
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 6 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Mounting (Wall Trim & Mounting Bracket Assembly) 2 of 2
Ceiling Trim resting on T-Bar
Tighten hex nuts to lock
Mounting Bracket in place
Lead Wire
Secure connections between continuous runs using Connector Blocks after all
luminaires have been mounted.
Note: Refer to steps on page 17 for details.
9
Install Ceiling Trim after all runs have been mounted and connected.
Note: Follow the steps on page 18 to install Ceiling Trim.
10
After all luminaires are mounted, adjust height and levelness of each luminaire
by tightening or loosening hex nuts on Mounting Brackets. Allow the weight
of the luminaire to be suspended by the Hanging Bracket while simultaneously
resting on the flange of the T-Bar.
Note: One person holds the luminaire and another person adjusts hex nuts.
11
Make wiring connections from driver to 1st PCB. Pull lead wires from luminaire
and make splice connections to lead wires from driver. Verify wiring diagram
before connecting.
13
Verify driver wire colors from wiring diagram, then connect luminaires to power
source. Drivers used for this product vary. Always confirm wiring diagram from
driver installation instructions before connecting.
15
If applicable, install end caps to ends of runs.
8
After all installation steps are complete and lighting is confirmed to be working,
install reflective film to runs.
Note: Follow the steps on page 19 to install reflective film.
17
Perform a continuity test before connecting luminaire to power source.
Refer to page 20 for continuity test step by step.
14
Apply mud to Wall Trim until completely covered and smooth. Allow to dry
completely before painting or sanding. Do not use pre-mixed mud compounds.
16
Drivers may be mounted on top of luminaire if suitable for your application.
Only mount drivers on top of luminaire if it is readily accessible, such as a
dropped tile ceiling. Position the driver in the center of luminaire and secure
using 1/4” #8 screws (by others). Do not mount drivers between segments.
Note: Driver size and location of mounting holes may differ from below example.
12
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 7 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Diagram of Assembly (Hanging Bracket Assembly)
Reflective Film
5/8” Drywall
Wall Stud
Wall Trim
Lens
Trim Retention Spring
Flange Ceiling Trim Ceiling Tile
Tie Wire
Flange
Tie Wire
Rail Bracket
Lock WasherHex Nut
Hanging Bracket Arm
Hex Screw
Channel
Hex Head Screw
(8-32 x 3”)
Connector Block
1/8” Mud
DIAGRAM OF ASSEMBLY
.06”
1.34”
4.0”
1.37”
4.81”
3.75”
Max. Height
DIMENSIONS
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 8 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Mounting (Hanging Bracket Assembly ) 1 of 2
Mount Wall Trim
Ceiling Line
6-1/8”
5/8” Drywall
T-Bar
Support WireWall Stud
Maintain
Continuous Edge
Ceiling Line
Mark Wall Stud
6”
4”
5/16”
Countersink Screw
Rail Bracket
Hex Nut
8-32 x 3”
Hex Head Bolt
Lock Washer
Slot
Hanging Bracket Arm
Do not install ceiling tiles until after installation of luminaires is complete.
Installation area must have at least 10” of overhead space.
1Determine number of Hanging Brackets required.
Note: Refer to the diagrams on page 14 as a guide.
5
If applicable, assemble Hanging Bracket Arms. Insert Hex Head Bolts through
slots on Hanging Bracket Arms and secure with washers and hex nuts.
6
Mark locations where each Rail Bracket will be installed along reference line.
Align the bottom of the Rail Bracket with the reference line and pre-drill using
proper drill bit for surface and screw size. Each rail must be mounted with a
minimum of two screws. Drill additional holes in Rail Brackets if necessary.
Note: Use 8/32 x 2” Countersink Screw (By others)
7
Install Hanging Bracket Arms to luminaire by sliding inverted Hex Head Bolts of
Hanging Bracket into the channels pictured below.
Do not slide into any other channels.
Note: All Hex Head Bolts must be vertical after mounting luminaire. If bolts are
crooked or slanted, the Hanging Bracket must be adjusted.
8
If applicable, install end caps to ends of runs.
9
Install T-Bar ceiling grid. Assemble the grid so there is a continuous edge
around grid for the Ceiling Trim to rest on. Hang the center of the T-Bar 6-1/8”
away from wall stud.
2
Hang or cut drywall along installation area so it is exactly 4” above ceiling line.
Measure exactly 6” above ceiling line and mark each wall stud in the installation
area. The ceiling line is 5/16” below to top edge of the T-Bar. Use a laser level
to ensure accurate relation to ceiling line, then draw a reference line connecting
each mark along the wall studs.
Note: Drywallers must hang drywall to the specifications. Only cut if necessary.
3
Mark locations along Wall Trim extrusion where it will be mounted to wall studs,
then drill holes as needed and mount to wall studs.
Note: Mount Wall Trim extrusion using at least 1 screw per 2’, rounded up.
4
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 9 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Mounting (Hanging Bracket Assembly ) 2 of 2
Tighten hex
nuts as needed
Ceiling Trim resting on T-Bar
Slide luminaire with Hanging
Bracket Arms onto Rail Bracket
Lead Wire
Mount luminaire to Rail Brackets by sliding luminaire with assembled Hanging
Bracket Arms into Rail Brackets. Ensure each Hanging Bracket rests at the
center of each Rail Bracket.
10 Secure a tie wire to each Hanging Bracket Arm after luminaires are set in place.
Note: Refer to the diagrams on page 7 for details.
14
Secure connections between continuous runs using Connector Blocks after all
luminaires have been mounted.
Note: Refer to steps on page 17 for details.
11
Install Ceiling Trim after all runs have been mounted and connected.
Note: Follow the steps on page 18 to install Ceiling Trim.
12
Make wiring connections from driver to 1st PCB. Pull lead wires from luminaire
and make splice connections to lead wires from driver. Verify wiring diagram
before connecting.
16
Verify driver wire colors from wiring diagram, then connect luminaires to power
source. Drivers used for this product vary. Always confirm wiring diagram from
driver installation instructions before connecting.
18
After all installation steps are complete and lighting is confirmed to be working,
install reflective film to runs.
Note: Follow the steps on page 19 to install reflective film.
20
Perform a continuity test before connecting luminaire to power source.
Refer to page 20 for continuity test step by step.
17
After all luminaires are mounted, adjust height and levelness of each luminaire
by tightening or loosening hex nuts on Hanging Bracket assembly.
Allow the weight of the luminaire to be suspended by the Hanging Bracket while
simultaneously resting on the flange of the T-Bar.
Note: One person holds the luminaire and another person adjusts hex nuts.
13
Apply mud to Wall Trim until completely covered and smooth. Allow to dry
completely before painting or sanding. Do not use pre-mixed mud compounds.
19
Drivers may be mounted on top of luminaire if suitable for your application.
Only mount drivers on top of luminaire if it is readily accessible, such as a
dropped tile ceiling. Position the driver in the center of luminaire and secure
using 1/4” #8 screws (by others). Do not mount drivers between segments.
Note: Driver size and location of mounting holes may differ from below example.
15
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 10 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Diagram of Assembly (Aircraft Cable Assembly)
5/8” Drywall
1/8” Mud
Wall Stud
Wall Trim
Lens
Trim Retention Spring
Flange Ceiling Trim Ceiling Tile
Tie Wire
Flange
Hex Screw
Channel
Connector Block
Reflective Film
Aircraft Cable Assembly
DIAGRAM OF ASSEMBLY
4.81”
.06”
1.34”
4.0”
6.50”
1.37”
DIMENSIONS
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 11 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Mounting (Aircraft Cable Assembly) 1 of 3
Ceiling Line
~7”
Aircraft Cable
Mounting Surface
Cable Gripper
Excess cable
Aircraft Cable
Cable Gripper
Hex Nut
Flat Bracket
Hex Nut
Hex Head Bolt
6-1/8”
5/8” Drywall
T-Bar
Support WireWall Stud
Maintain
Continuous Edge
Ceiling Line
Mount Wall Trim
Ceiling Line
4”
Do not install ceiling tiles until after installation of luminaires is complete.
The installation area must have at least 10” of overhead space.
1Determine number of Aircraft Cable Assemblies required.
Note: Refer to the diagrams on page 15 as a guide.
5
Install T-Bar ceiling grid. Assemble the grid so there is a continuous edge
around grid for the Ceiling Trim to rest on. Hang the center of the T-Bar 6-1/8”
away from wall stud.
2
Hang or cut drywall along installation area so it is exactly 4” above ceiling line.
Note: Drywallers must hang drywall to the specifications. Only cut if necessary.
3
Mark locations along Wall Trim extrusion where it will be mounted to wall studs,
then drill holes as needed and mount to wall studs.
Note: Mount Wall Trim extrusion using at least 1 screw per 2’, rounded up.
4
If applicable, assemble Aircraft Cable Assemblies. Install hex nuts about halfway
down each hex head bolt, then insert bolts through flat bracket and secure with
hex nuts.
6
Determine locations where Aircraft Cables will be mounted overhead. Secure to a
sturdy surface, such as studs, using hardware (by others) that is rated for the
weight of the luminaire.
Note: Do not hang luminaire from weak material such as drywall or plywood.
7
Secure Aircraft Cable Assemblies to mounting surface. The top of the assembly
should rest approximately 7” above ceiling line. Adjust position of assembly along
aircraft cable using cable gripper. Do not trim excess cable at this time.
8
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 12 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Mounting (Aircraft Cable Assembly) 2 of 3
Ceiling Trim resting on T-Bar
Trim excess cable
Adjust length as needed
Tighten hex nuts
to secure in place
Slide luminaires onto
Aircraft Cable Assemblies
Unscrew & lift
Press down & hold
Pull cable
Adjust Cable Gripper by unscrewing locking mechanism. Press down and hold
the threads where cable feeds through. Pull cable from the exit. Let go of threads
to lock in place, then replace locking mechanism.
9
Slide luminaires onto Aircraft Cable Assemblies. Adjust positioning of lower hex
nut if needed to allow assemblies to slide in easily. Always install corners first.
10
If applicable, install end cap to end of run.
11
After all luminaires have been mounted, secure Aircraft Cable Assemblies to
luminaire by tightening lower hex nuts. All aircraft cables must rest in a vertical
position. Do not allow aircraft cables to rest at a slant or angle. Adjust as needed.
Note: The position of the Aircraft Cable Assemblies may deviate from the
spacing diagrams due to variations within the installation area. Ensure all
luminaires are appropriately balanced.
12
Secure connections between continuous runs using Connector Blocks after all
luminaires have been mounted.
Note: Refer to steps on page 17 for details.
13
Install Ceiling Trim after all luminaires have been mounted and connected.
Note: Follow the steps on page 18 to install Ceiling Trim.
14
After all luminaires are mounted, adjust height and levelness of each luminaire
by adjusting cable gripper. Allow the weight of the luminaire to be suspended by
the aircraft cable while simultaneously resting on the flange of the T-Bar.
Note: One person holds the luminaire and another person adjusts cable gripper.
15
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 13 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Mounting (Aircraft Cable Assembly) 3 of 3
Lead Wire
Make wiring connections from driver to 1st PCB. Pull lead wires from luminaire
and make splice connections to lead wires from driver. Verify wiring diagram
before connecting.
17
Perform a continuity test before connecting luminaire to power source.
Refer to page 20 for continuity test step by step.
18
Verify driver wire colors from wiring diagram, then connect luminaires to power
source. Drivers used for this product vary. Always confirm wiring diagram from
driver installation instructions before connecting.
19
After all installation steps are complete and lighting is confirmed to be working,
install reflective film to runs.
Note: Follow the steps on page 19 to install reflective film.
21
Apply mud to Wall Trim until completely covered and smooth. Allow to dry
completely before painting or sanding. Do not use pre-mixed mud compounds.
20
Drivers may be mounted on top of luminaire if suitable for your application.
Only mount drivers on top of luminaire if it is readily accessible, such as a
dropped tile ceiling. Position the driver in the center of luminaire and secure
using 1/4” #8 screws (by others). Do not mount drivers between segments.
Note: Driver size and location of mounting holes may differ from below example.
16
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 14 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Spacing Diagrams (Hanging Bracket Assembly)
1’
ALS500T-SWM
Hanging Bracket
Rail Bracket
ALS500T-SWM
2’ - 5’
Hanging Bracket
Rail Bracket
ALS500T-SWM
6’ - 8’
Hanging Bracket
Rail Bracket
• For luminaires 1’ long,
use 1 Rail Bracket and 2 Hanging Brackets.
• Install 2 Hanging Brackets, 2” from each end of 1 Rail Bracket.
• Align the 1’ Rail Bracket with the 1’ luminaire.
• For luminaires 2’ - 5’ long,
use 2 Rail Brackets and 2 Hanging Brackets.
• Install 1 Hanging Bracket in the center of each Rail Bracket.
• Align the Rail Brackets with the end of the luminaire.
• For luminaires 6’ - 8’ long,
use 3 Rail Brackets and 3 Hanging Brackets.
• Install 1 Hanging Bracket in the center of each Rail Bracket.
• Align each Rail Bracket with the center and ends of fixture.
1’ LUMINAIRE
2’ - 5’ LUMINAIRE
6’ - 8’ LUMINAIRE
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 15 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Spacing Diagrams (Aircraft Cable Assembly)
ALS500T-SWM
1’ - 5’
Aircraft Cable Assembly
4”
ALS500T-SWM
6’ - 8’
Aircraft Cable Assembly
4”
• For luminaires 1’ - 5’ long, use 2 Aircraft Cable Assemblies per luminaire.
• Install each assembly about 4” from each end of luminaire.
Note: Location may vary depending on accessibility mounting surfaces. Ensure each luminaire is balanced.
• For luminaires 6’ - 8’ long, use 3 Aircraft Cable Assemblies per luminaire.
• Install 1 assembly centered and 2 assemblies about 4” from each end of luminaire.
Note: Location may vary depending on accessibility mounting surfaces. Ensure each luminaire is balanced.
1’ - 5’ LUMINAIRE
6’ - 8’ LUMINAIRE
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 16 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Spacing Diagrams (Mounting Bracket Assembly)
ALS500T-SWM
1’ - 5’
4” Mounting Bracket Wall Trim
ALS500T-SWM
6’ - 8’
4” Mounting Bracket Wall Trim
• For luminaires 1’ - 5’ long, use 2 Mounting Brackets per luminaire.
• Install each bracket about 4” from each end of luminaire.
Note: Location may vary depending on accessibility mounting surfaces. Ensure each luminaire is balanced.
• For luminaires 6’ - 8’ long, use 3 Mounting Brackets per luminaire.
• Install 1 bracket centered and 2 brackets about 4” from each end of luminaire.
Note: Location may vary depending on accessibility mounting surfaces. Ensure each luminaire is balanced.
1’ - 5’ LUMINAIRE
6’ - 8’ LUMINAIRE
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 17 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Connecting Continuous Runs
Allen Screw
Continuous Connector
Lock Washer
Sequence Labeling
Male Block
Quick
Disconnects
Sequence Labeling
Female Block
Extrusions aligned
Tighten with allen wrench
Make cuts to extrusion and lens if necessary. Do not cut PCB, wiring, or
accessories. Only use a miter saw equipped with a blade for cutting metal.
Note: If applicable, remove Connector Blocks from extrusion before cutting.
1Position luminaires together and align the screw of the Male Block to meet the
Female Block. Tighten Allen Screws using provided Allen Wrench to close the
gap until luminaires meet. Only tighten screws until extrusion edges meet with
no gaps. Over-tightening screws will create separation at the seam.
Tip: One person holds the luminaire together, ensuring there is no gap, while
another person tightens screws.
3
If applicable, insert one Allen Screw with Lock Washer into each Male Block.
Note: Ensure sequence labeling is in the correct sequence (A, B, C, etc.)
2
Connect disconnects between luminaires, if applicable. Ensure connected runs
do not exceed load of power supply.
Note: Refer to Electrical section on first page for details on calculating load.
4
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 18 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Ceiling Trim
Keep Trim Retention Springs
4” away from this edge
Trim Retention Spring
4’ 4’ 4’ 4’
16’
Cut Line
8’
2’
Trim Retention SpringCeiling Trim
4’ 4’ 4’ 4’
16’
8’2’ 6’
Seams between trim and fixtures not aligned
Install Trim Retention Springs to ceiling trim. Use one clip per 2’, or two clips
per segment under 4’. Install clips 4” from each edge, evenly spaced.
3
Measure and cut a 2’ section from one of the Ceiling Trim segments.
2
Measure installation area to determine required lengths of Ceiling Trim.
Example: 16’ required two 8’ sections of Ceiling Trim.
1Install Ceiling Trim with Trim Retention Springs to mounted luminaires.
Ensure all springs snap into channel and that trim is not loose or sagging.
Note: Place trim pieces carefully, they can not be removed after installing.
Note: Ensure placement Trim Retention Springs is at least 4” from edges of
luminaire where wiring is present.
4
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 19 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Reflective Film (ALS500T-SWM-RF-98)
2
Second, insert edge of film
into top wall-side corner
gap between the wall trim
and top of extrusion.
First, insert edge of film into
bottom ceiling-side corner gap
between lens and extrusion.
Do not cover lens with film.
Extrusion
Wall Trim
Lens
1
• Follow the below diagrams and steps if applicable to your installation.
• Only install Reflective Film after all other installation requirements are
complete. Lighting must be tested and in working order, and wall must be
mudded, painted, and completely dry before beginning.
• Reflective Film requires a minimum of two people to ensure a secure and
correct installation.
• Use a puller stand to prevent damage to the film while installing.
• Installers must wear gloves while handling Reflective Film.
• The Reflective Film is two-sided. Place the textured side facing downward.
The smooth side should only be facing upward.
INSTALLATION GUIDELINES
• Stable in humid environments
• Anti-static
• Abrasion resistant
• Continuous thermal stability up to 100°C
• Compatible with the following cleaning solutions: dilute ammonia, soap
solutions, Clorox Wipes, Pine-Sol, and Formula 409
FEATURES & MAINTENANCE
SPECIFICATIONS
REFLECTANCE @ 550NM 97.5 ± 0.8% (ASTM E1164)
L* VALUE > 98.9 (ASTM E308)
A VALUE -0.35 ± 0.25 (ASTM E308)
B VALUE 0.90 ± 0.30 (ASTM E308)
GLOSS (60°) < 5.0% (ASTM D2456)
THICKNESS 205 µm ± 15 (Ono Sokki EG225)
TENSILE STRENGTH 165 MPa (ASTM D882)
DEFORMATION TEMPERATURE 130°C (JIS K7196-1991)
MELT TEMPERATURE 255°C (ASTM D3418)
UL RELATIVE THERMAL INDEX 105°C (UL746)
Installation Area
Reflective Film
Puller Stand
One person installs Reflective Film
according to the instructions below.
Another person feeds film from
puller stand to installer, ensuring
that film is not disturbed in the process.
Installers must wear gloves
Miter Square
Reflective Film
Rough edge
Location of new cut
Clean edge
Cut a 1’ section of Reflective Film and practice installing to get a feeling for how
it bends and forms in the luminaire. The film cannot be corrected if it is bent,
folded, wrinkled, or kinked during installation.
1
Place roll of Reflective Film onto wire puller stand. Gently pull film from roll
and feed to installer as needed. Check that the textured side is facing downward
when pulling.
3
Place beginning edge all the way to the end, so the edge of the film sits flush to
the end cap.
4
At the end of the run, estimate how much more film will be needed. Make small
cuts at the end of the film and test fit it. Repeat if necessary until the film meets
the end cap flush.
5
Check along entire run that Reflective Film is installed correctly. Ensure lens is
not covered by film and that it is securely tucked into each edge along the run.
6
If applicable, cut the end of the sheet so it has a smooth and even edge.
Tip: Use a tool to ensure an accurate cut.
2
CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
© CALI. All rights reserved. CALI reserves the right to make changes or withdraw specifications without prior notice.
4 / 2 / 2022 / Rev 4
Page 20 of 20
ALS500T-SWM-FG
INSTALLATION INSTRUCTIONS
Troubleshooting & Continuity Test
Damaged LED
Poor Quality Cut
Damaged Connection
Broken Solder Connection
Foreign Object Metal Flakes
Damaged Board
1.
Turn off power before beginning. Check for any damage to the circuit in the LED board.
If there is excessive damage and the circuit is broken, the board must be replaced.
3.
Check to make sure cuts in the board are clean. Poor quality cuts to the LED board will
cause damage to the circuit, resulting in dim, flickering, or lightless LEDs.
4.
Check connections between LED terminals and, if applicable, check soldered connections.
2.
Check for metal particles or other foreign objects causing the short.
TROUBLESHOOTING TIPS
• Do not reset the breaker multiple times
• If the unit is overloaded, the breaker will trip, shutting off the transformer and lights
• If the breaker reset button has been held down by hand or any type of pressure, such as duct
tape, or if the breaker has been reset multiple times without troubleshooting, the unit will:
- Burn the transformer bobbin
- Burn the thermal or magnetic breaker
- Burn the primary or secondary wires due to high amperage caused by overload
- Short circuit in line which will not allow the breaker to reset
- Damage the lighting
1
. Turn power off before beginning. Verify power is turned off by using a non-contact circuit
tester. Touch the probe of the tester to positive wire of the power source. The tester will
light up if an electrical current is detected.
3. Verify that your tester is functional by touching probes together. The tester should light up,
beep, or read 0Ω (ohms) of resistance.
4. Touch the red probe to the positive (+) wire and the black probe to the negative (-) wire.
If a conductive path is formed between the positive and negative wires, the multimeter will
beep, flash, or read 0Ω (ohms). Troubleshoot to identify the malfunction in the line.
If there is no conductive path, the multimeter will not show any feedback.
5. Touch the red probe to the fixture extrusion and the black probe to the positive (+) wire.
If a conductive path is formed between the extrusion and the positive wire, the multimeter
will beep, flash, or read 0Ω (ohms). Troubleshoot to identify the malfunction in the line.
If there is no conductive path, the multimeter will not show any feedback.
6. Touch the red probe to the fixture extrusion and the black probe to the negative (-) wire.
If a conductive path is formed between the extrusion and the negative wire, the multimeter
will beep, flash, or read 0Ω (ohms). Troubleshoot to identify the malfunction in the line.
If there is no conductive path, the multimeter will not show any feedback.
7. Set voltmeter to DC voltage and test power source. Confirm the correct voltage before
connecting lighting to power source. If voltage reading is more than 1 volt higher than the
marked output voltage, there is a problem with the power source or driver.
8. Connect power connector to power source. If LEDs do not turn on, flip polarity (+ -) or
power source connection to power connector.
CONTINUITY TEST
A continuity test is performed to determine if electricity can pass through two points on
an electrical circuit. This helps identify shorts or malfunctions in the line or fixture.
Use a
multimeter or continuity tester to perform the steps below.
•
Always perform a continuity test before connecting lighting to power source.
•
Malfunctions are not always as obvious as the lights not turning on.
•
A short or malfunction in the line or fixture will cause damage over time, ultimately damaging
the lighting and voiding warranty.
(-)
(+)
Red Probe
Black Probe
LED Lighting
(-)
(+)
Black Probe
LED Lighting
Red Probe
(-)
(+)
Black Probe
LED Lighting
Red Probe
2.
Setup your tester. First insert the black probe lead into the COM jack, then insert the red
probe lead into the VΩ jack.
1
2
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