Carolina DSF640 User manual

INSTRUCTIONS
DSF640 LED FLOOD LIGHT
READ THOROUGHLY BEFORE INSTALLING
OVERVIEW
This product was designed from the ground up to be the most efficient and reliable LED flood lighting product on the market. Please read and understand all
installation instruction prior to installing. Should you have any questions, do not hesitate to contact your local agent or Carolina High Mast for clarification.
UNPACKING
The DSF640 ships preassembled in one shipping package. The package is
designed to minimize risk of damage to the luminaire during shipping and
handling. It is recommended that the DSF is not removed from the
packaging unless it is to be immediately mounted on the support structure.
Each package contains an exterior label that identifies the wattage and
lighting distribution. In pre-aimed lighting systems, each package also
uniquely identifies the appropriate tower and cross arm location.
WARNING: Removing the fixture from the packaging and setting on the
ground could damage the glass or exterior finish. Care should be taken to
protect the unit if it is to be removed from the packaging and not
immediately bolted to the support structure.
INSTALLATION
A. TRUNION ORIENTATION
The DSF can be utilized in one of three different trunion orientations.
The luminaire ships from the factory in the ‘Trunion Down’
orientation. To achieve another trunion orientation, remove the
aiming bolts (M6) and loosen the main trunion bolts on the side of
the fixture housing (M8). Rotate the trunion to the desired
orientation and reinstall the trunion aiming bolts in the threaded
holes of the fixture housing that be align for the desired application.
The aiming bolts are designed to be installed 180 degrees from each
other.
a. TRUNION DOWN ORIENTATION
The DSF is typically mounted with the trunion below the
luminaire. This mounting orientation is typical of the
HID luminaires the DSF is designed to replace.
b. TRUNION UP ORIENTATION
The DSF can be mounted with the trunion above the
luminaire with the fixture body below the mounting
location. This orientation is useful when utilizing the
DSF640 on a CHM lowering device system or when
replacing certain existing HID installations.
c. TRUNION OUT ORIENTATION
The DSF can be mounted to a vertical surface such as a
building wall with the trunion horizontal to the ground.
This orientation makes mounting to vertical surfaces
easier.
B. MOUNTING
The DSF640 flood light is provided with a heavy duty mounting
trunion. The mounting trunion has clearance for a ¾” main
attachment bolt. Raise the luminaire into position and attach the
main ¾” trunion bolt. Snug tight the main bolt to hold the luminaire
in place. The luminaire shall be adjusted to the proper left-right
aiming angle by rotating the luminaire on the main trunion bolt.
Once the proper left-right aiming angle has been achieved, tighten
the main trunion bolt to 80-90 ft*lb of torque. NOTE: Refer to
aiming instructions for additional details on proper aiming
procedure.
C. WIRING
Make all connections in accordance with the National Electric Code
and any applicable local code requirements.
a. WIRING TO EXTERNAL JUNCTION BOX OR WIRE WAY
The power cable should be routed to external wire way
or junction box that is within 24” of the fixture mounting
location. A weatherproof cord grip shall be utilized at
the junction location to prevent ingress of water into the
junction box/wire way.The loose end of the DSF power
cable shall be connected to incoming power in
accordance with local and national electric code
requirements. WARNING: In a L-N-G system, ensure
the system neutral is connected to the incoming white
wire only. G is exclusively reserved for electrical ground
and B is always hot (Line).
b. WIRING WITH OPTIONAL BRAD HARRISON STYLE
CONNECTOR
With this option, the fixture power tail is pre-wired in
the factory with a 3 pole, weatherproof connector
system designed to connect to the CHM pre-wired
sports lighting system. Simply connect the fixture
connection to the power plug at the luminaire location
on the crossarm.
c. 0-10V DIMMING CONNECTION
The DSF comes with a secondary 2 conductor power
cable for dimming control of the luminaire. From the
factory, the dimming cable is sealed with a
The included installation instructions are not to be considered to cover all details. General best practice and safety precautions should be taken when working with
electrical equipment such as this. Should there be any uncertainty about the guidelines contained herein, Carolina High Mast or an Carolina High Mast
representative should be contacted immediately for further guidance.
Document Revision 06/10/14

INSTRUCTIONS
DSF640 LED FLOOD LIGHT
weatherproof seal cap. If dimming is to be utilized, cut
off the weaterproof cap and strip back the cables. Route
the dimming wires in accordance with B.a and connect
to incoming control wires. NOTE: The seal cap on the
dimming cable shall not be removed unless the 0-10V
function shall be utilized and connected in accordance
with these instructions.
d. 347V AND 480V SYSTEMS
For fixtures optioned with the T3 or T4 option, a 750VA
Toroidal transformer will be factory integrated into the
luminaire to step down incoming power to 277V. The
enclosure will include a dedicated weatherproof cord
grip for incoming power and outgoing power to the
luminaire. The wiring from the transformer to the
luminaire will be factory assembled and shall not be
modified in the field. The incoming power wires will
include a field ready butt splice joint. Route the
incoming power via a 16/3” SO cable through the cord
grip and connect incoming power to the supplied butt
splice joints. Once wiring is complete, ensure the cable
grip is properly tightened on the incoming power cable.
WARNING: In a L-N-G system, ensure the system
neutral is connected to the incoming white wire only. G
is exclusively reserved for electrical ground and B is
always hot (Line).
AIMING PREPARATION
Prior to aiming of the flood lighting fixtures, it is critical to ensure the
proper distributions are located in the appropriate location on the support
structure. The label on the underside will show the complete part number
including the light distribution. Distributions are in degrees and include
15D, 20D, 30D, 45D and 60D beam angles. Distributions should be matched
to the supplied aiming array illustrating the fixture array, aiming angles and
specific distribution.
DEGREE AIMING
The DSF is provided with a horizontal and vertical aiming indicator. These
aiming indicators can be used for general aiming indication. NOTE: If
precision aiming is required, the target aiming process should be followed.
Contact CHM for detailed target aiming instructions.
In the pre-aimed configuration, both the horizontal and vertical aiming
indicators with be marked with the appropriate aiming settings. Adjust the
luminaire until the aiming mark aligns with the aiming bolt. IF the fixture is
not pre-aimed from the factory, follow the aiming steps below. NOTE: The
vertical aiming bolts are Allen head socket bolts. The hardware is METRIC
sizing. Use of incorrectly sized hardware to tighten these bolts could
damage the fasteners.
To properly aim the DSF640, the mounting structure shall have mounting
holes in accordance with the CHM mounting detail. Contact CHM
Industries for the drill pattern necessary to support the DSF640. If
purchasing mounting structure from CHM, the plates will be factory drilled
to accommodate the DSF.
AIMING VIA INCLINOMETER
RECOMMENDED METHOD IN LIEU OF TARGET AIMING
1. The pole and crossarms must be braced so that they are both
LEVEL (parallel) with the ground.
2. Each floodlight is attached to the crossarm(s) so that the glass
lens is LEVEL (parallel) with the ground.
3. Loosen the (4) aiming bolts (2 per side) and (2) main trunion
bolts. The aiming bolts are M6 and the main trunion bolt is
M8. An inclinometer is positioned on the glass lens
perpendicular to the crossarm. The down angle adjustment
that is indicated in the square boxes of the fixture
arrangement and aiming schedule is made. The bolts that
attach the trunnion to floodlight housing are tightened. Match
mark the location of the aiming bolt (Sharpie permanent
marker will work here) and the trunion aiming angle so that
the fixture can be repositioned to the correct location.
4. The vertical aiming bolts and main trunion bolt are then
loosened and the floodlight is rotated back to its original
horizontal (level) position in preparation for Left or Right
adjustment. Retighten the bolts.
5. The inclinometer is positioned on the glass lens parallel to the
crossarm. The crossarm attachment bolts are loosened, the
Left or Right angle adjustment is made, and the bolt is
retightened.
6. Finally, the trunnion/fixture bolts are loosened and the
floodlight is rotated to its final vertical position (against the
reposition stop). Make sure that the stop is not bent by rapid
movement during rotation. Securely tighten all bolts and
screws.
AIMING VIA AIMING BOLTS
1. Mount the luminaire to the mounting structure.
2. Loosen the (4) aiming bolts (2 per side) and (2) main trunion
bolts. The aiming bolts are M6 and the main trunion bolt is
M8. Adjust the vertical aiming angle until the aiming bolt align
with the appropriate down angle as shown on the aiming array
provided by CHM.
3. Loosen the main ¾” attachment bolt. Rotate the fixture left or
right to the appropriate angle as shown on the aiming array
provided by CHM. Once the proper left-right aiming angle has
been achieved, tighten the main trunion bolt to 80-90 ft*lb of
torque.
18/3 POWER CABLE FOR
INCOMING 120V-277V
POWER
18/2 POWER CABLE FOR 0-
10VDC CONTROL IF
NEEDED.
LED DRIVERS, FACTORY
WIRED.
The included installation instructions are not to be considered to cover all details. General best practice and safety precautions should be taken when working with
electrical equipment such as this. Should there be any uncertainty about the guidelines contained herein, Carolina High Mast or an Carolina High Mast
representative should be contacted immediately for further guidance.
Document Revision 06/10/14

INSTRUCTIONS
DSF640 LED FLOOD LIGHT
EXTERNAL VISOR
The external visor for the DSF640 is designed to minimize up lighting, lower
property line spill and reduce direct view of the light sources from off-axis
viewing angles. The external visor ships separate of the DSF luminaire to be
installed in the field. The external visor consists of a light absorbing top
visor and clamp ring that is designed to clamp around the black housing of
the LED array.
1. Once the fixture is installed on the mounting structure, remove
the external visor from the shipping package.
2. Slide the visor ring around the LED housing until the visor
bracket is making contact with the gray fixture housing body.
3. Align the visor so that the clamp bolt is on the bottom side of
the light emitting surface.
4. Torque the main visor clamp bolt until the visor is tightly
affixed to the LED housing.
ADDITIONAL SAFETY NOTES
1. High Intensity Discharge (HID) lamps contain mercury and
should be disposed of in accordance with Federal, State and
Local codes.
2. Allowed the luminaire to cool to ambient temperature prior to
handling.
3. This luminaire is a high wattage, high voltage piece of
equipment. There is a RISK OF ELECTRICAL SHOCK when
working on this product. Installation, service and maintenance
should be conducted by properly trained personnel only.
4. Do not fuse the incoming ground or neutral line to the
luminaire; this can cause electrical shock and death.
5. Do not modify or retrofit this product without the express
authorization of CHM.
CLEANING AND MAINTENANCE
The DSF is designed to be as maintenance free as possible over the typical
design life of an LED luminaire. While the DSF includes impressive levels of
ingress protection, buildup of environmental contaminants can reduce
overall fixture efficiency.
1. The glass on the optical assembly is high strength tempered
glass. It can be cleaned with a standard cleaning solution like
Windex. It is strongly recommended that a microfiber cloth is
used to clean the glass to avoid scratches in the surface.
2. The perforated body of the DSF is designed to allow the airflow
necessary to cool the LED array to extremely low and stable
operating conditions. In certain extreme environments like
arena applications where dirt is utilized (rodeo, motorcross,
monster truck, etc), extreme levels of dirt can build up on
luminaires. In these applications, it is suggested that the DSF is
inspected for dirt build up on the cooling apparatus. Should
there exist an excessive level of dirt built up, it is suggested
that the luminaire be blown out with compressed air. This is
not unique to the DSF and is also suggested for standard HID
and competitive LED products.
3. The DSF is covered by a 5 year complete replacement warranty
(longer terms available) and will not require any internal
maintenance over that term.
VERTICAL AIMING BOLT
ALIGNS WITH AIMING
ANGLE STAMPED ON
HORIZONTAL AIMING BOLT ALIGNS
WITH AIMING ANGLE LABELED ON THE
TRUNION
SLOT FOR AIMING BOLT
HOLE FOR MAIN TRUNION BOLT
EXTERNAL VISOR ASSEMBLY
VISOR CLAMP BOLT
LED HOUSING. VISOR CLAMPS
AROUND THIS FEATURE.
The included installation instructions are not to be considered to cover all details. General best practice and safety precautions should be taken when working with
electrical equipment such as this. Should there be any uncertainty about the guidelines contained herein, Carolina High Mast or an Carolina High Mast
representative should be contacted immediately for further guidance.
Document Revision 06/10/14