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CALI alumLEDs ALS500T-SWM-FG User manual

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CALIFORNIA ACCENT LIGHTING, INC.
2820 E. Gretta Lane, Anaheim, CA 92806
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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
ph. 800.921.CALI (2254) | fx. 714.535.7902 | [email protected]om | calilighting.com
© 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