CoeLux 45 SQUARE User manual

Lighting unit
CoeLux®45 SQUARE
Assembling and
installation instructions
CoeLux S.r.l.
Via Cavour, 2
22074 Lomazzo –Como - Italy
Tel. [phone]
www.coelux.com

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INDEX
1INTRODUCTION ................................................................................... 4
1.1 CONVENTIONAL SYMBOLS USED IN THE MANUAL ....................................................................... 4
1.2 ABBREVIATIONS............................................................................................................................ 4
1.3 UNITS OF MEASUREMENT ............................................................................................................ 4
2CHARACTERISTICS................................................................................ 5
2.1 DESCRIPTION OF THE PRODUCT ................................................................................................... 5
2.2 TECHNICAL DATA AND CHARACTERISTICS .................................................................................... 5
2.3 PRODUCT IDENTIFICATION ........................................................................................................... 7
2.4 STANDARDS .................................................................................................................................. 7
2.5 GENERAL SAFETY WARNINGS ....................................................................................................... 7
2.5.1 OPERATIONS TO BE AVOIDED............................................................................................... 8
3QUALIFICATIONS OF THE OPERATORS .............................................. 10
4TRANSPORTATION, MOVEMENT AND STORAGE .............................. 11
4.1 PACKAGING AND TRANSPORT .................................................................................................... 11
4.1.1 UNPACKING ........................................................................................................................ 11
4.2 MOVEMENT OF THE PARTS ........................................................................................................ 12
4.3 STORAGE..................................................................................................................................... 12
5PRE-INSTALLATION ............................................................................ 13
5.1 TOOLS NOT SUPPLIED BUT NECESSARY FOR INSTALLATION....................................................... 13
5.2 INITIAL CLEANING ....................................................................................................................... 17
5.2.1 CLEANING PROCEDURE....................................................................................................... 17
6INSTALLATION.................................................................................... 20
6.1 PERMITTED APPLICATIONS ......................................................................................................... 20
6.2 SPACE PLANNING........................................................................................................................ 20
6.3 GENERAL MOUNTING INSTRUCTIONS ........................................................................................ 20
7ASSEMBLING...................................................................................... 21
7.1 ASSEMBLY PROCEDURE .............................................................................................................. 21
7.2 ASSEMBLY SEQUENCE................................................................................................................. 23
7.2.1 SMALL MIRROR INSTALLATION........................................................................................... 23
7.2.2 LARGE MIRROR INSTALLATION ........................................................................................... 26
7.2.3 COELUX® PANEL INSTALLATION.......................................................................................... 29
7.2.4 PROJECTOR INSTALLATION ................................................................................................. 30
7.2.5 SILICA-GEL INSTALLATION AND REPLACEMENT.................................................................. 32

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7.2.6 AIR COLLECTORS INSTALLATION (compulsory for UL certified systems) ............................ 33
7.2.7 MOUNTING OF WALL FIXING STIRRUPS AND PLATES......................................................... 34
7.2.8 LIFTING AND PLACEMENT OF THE DARK BOX..................................................................... 35
7.2.9 EXTERNAL MIRROR ASSEMBLY............................................................................................ 37
8ENCUMBRANCE, CONNECTIONS AND CHECKS ................................. 39
8.1 SAFETY DISTANCES AND VOLUME .............................................................................................. 39
8.2 CONNECTIONS ............................................................................................................................ 40
8.2.1 VENTILATION CONNECTIONS (ONLY POSSIBLE ON PROJECTOR 74-00013-01)................... 40
8.2.2 ELECTRICAL CONNECTIONS ................................................................................................ 41
8.3 CHECKS ....................................................................................................................................... 42
9OPERATIONS AND USE ...................................................................... 43
10 MAINTENANCE .................................................................................. 44
10.1 DISASSEMBLY OF THE UNIT ........................................................................................................ 44
10.2 DEMOLITION AND DISPOSAL ...................................................................................................... 44
11 ANNEXES............................................................................................ 45
11.1 VENTILATION KIT ........................................................................................................................ 45
11.1.1 CHANGING OF STEP “PROJECTOR INSTALLATION” ............................................................. 45
11.2 POWER CONNECTIONS FOR CB CERTIFICATION ......................................................................... 47
11.2.1 ASSEMBLY OF CABLE GLAND .............................................................................................. 47
11.2.2 USE OF TERMINALS BOX FOR CONNECTION OF POWER SUPPLY CABLES........................... 48
11.3 EXTRAORDINARY CLEANING PROCEDURE................................................................................... 51
11.3.1 SCOPE ................................................................................................................................. 51
11.3.2 FIELD OF APPLICATION ....................................................................................................... 51
11.3.3 TERMS AND DEFINITIONS ................................................................................................... 51
11.3.4 PROCESS DEVELOPMENT.................................................................................................... 51
12 CONTACTS.......................................................................................... 56
13 COPYRIGHT ........................................................................................ 56

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1INTRODUCTION
NOTE:
This manual is expressly intended for installation technicians.
Operators appointed to assembly and installation of CoeLux products must carefully read this
entire manual before installing, assembling and starting the unit, as well as before all
maintenance operations.
This manual must always be used and maintained in good conditions.
Do not remove, tear or arbitrarily change any of part of it.
Illustrations and drawings should only be considered as general references and are not
necessarily precise.
The images and technical specifications that appear in the manual are not binding and may be
changed without prior notice.
This manual consists of a total of 56 pages + annexes.
1.1 CONVENTIONAL SYMBOLS USED IN THE MANUAL
CAUTION !
This symbol means that the operator must pay great attention in order to avoid wounds and
damages to the personnel, breaks or fire to the unit.
WARNING:
This symbol means that the operator must pay attention in order to avoid inconveniences to the
personnel and / or possible damages to or bad running of the unit.
NOTE:
This symbol means specific technical indications or it emphasises important information.
This symbol shows the connection to parts or annexes of the manual, or the need to consult other
different documents.
If necessary, other auxiliary symbols can be employed.
1.2 ABBREVIATIONS
Sec. = section
Chap. = chapter
Par. = paragraph
Fig. = figure
Tab. = table
1.3 UNITS OF MEASUREMENT
Except where indicated otherwise, the used measurement units are those required by the
International System (SI).

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2CHARACTERISTICS
2.1 DESCRIPTION OF THE PRODUCT
CoeLux® 45 SQUARE is a recessed lighting unit: partially hidden by the false wall and the false
ceiling, it artificially simulates natural light of sky and sun, even in a fully closed space. CoeLux®
45 SQUARE must be installed on the wall.
CoeLux® 45 SQUARE includes a LED light source, glass optical components, a CoeLux® plastic
panel, all housed in a single metallic structure in the false wall, plus a mirror recessed in the false
ceiling.
WARNING:
CoeLux® 45 SQUARE installation and use is limited to indoor environments that comply with
essential requirements reported in the table below. It is forbidden any uneven use of the product,
respect to restriction report in this guide, which may cause hazards to health and safety of people,
animals and goods, and product malfunctioning. CoeLux s.r.l. is not liable for any injury to people,
animals or goods derived from an incorrect installation and/or improper use of the product (or
different from directives reported in the present guide).
For particularly severe environmental conditions (daily temperature range excide 15°C and
maximum relative humidity higher than 60%) support machines for active air treatment are
needed: please contact us for the scope
2.2 TECHNICAL DATA AND CHARACTERISTICS
Features
Measure unit
Value
MECHANICAL
Dark-box encumbrance on the wall
mm
1675 x 691 x 2375
in
65.9 x 27.2 x 93.5
Overall dimensions
mm
1685 x 1541 x 2375
in
66.3 x 60.7 x 93.5
Percived skylight dimensions
mm
980 x 980
in
36.8 x 36.8
Weight
Kg (lb)
300 (660)
ELECTRICAL (Projector)
Voltage (frequency) of supply
V (Hz)
100 –240 (50/60)
Connection
-
Phase + Neutral + PE
Maximum (typical) power consuption
W
300 (270)
Insulation class
IEC standards
Class I
Marking
CE, UL, FCC

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ENVIRONMENTAL (equipment intended for internal use)
Minimum / maximum operating temperature
°C
10 / 40
Maximum operating relative humidity
%
95 (non condensing)
Tab. 1 Data and features of the product
CoeLux® 45 SQUARE appears as a steel external case.
It may also be mounted on normally inflammable surfaces
For all lighting data, please see the product technical sheet. Contact CoeLux S.r.l. to receive them
or to receive further information and clarifications.
Fig. 1 Dimensions in mm (inch)
2375
(93.5)
21
(0.8)
670
(26.4)
691
(27.2)
1685
(66.3)
1541
(60.7)

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2.3 PRODUCT IDENTIFICATION
On the LED projector is located a label indicating the Serial Number and the Part Number;
communicate these numbers to CoeLux S.r.l. for any request.
Fig. 2 Label with Part Number e Serial Number
2.4 STANDARDS
CoeLux® 45 SQUARE meets the essential requirements of 2014/35/UE, 2014/30/UE, 2011/65/UE,
2012/19/EU directives for which the relevant harmonised standards were applied.
Moreover, CoeLux® 45 SQUARE holds the UL certification for Canada and U.S.A. (File E476417)
and FCC certification (in accordance with Cfr 47 part 15 –Subpart B- 15.107 e 15.109).
2.5 GENERAL SAFETY WARNINGS
CAUTION !
Read the entire user manual since it contains important information on correct installation and
operation. Follow indications reported in the present guide to avoid fire and accidents during
product installation and use.
The warranty is null and void in case of damages due to the inobservance of instructions and
warnings reported in the present guide. CoeLux s.r.l. is not liable for any injury to people, animals
or goods derived from inobservance of instruction and warnings reported in the present guide.
Moreover CoeLux s.r.l. does not assume any responsibility derived from an incorrect installation
and/or assembly (or different from directives reported in the present guide).
CAUTION !
Only personnel qualified by CoeLux s.r.l. can perform assembly, installation and inspection
operations. Fixing operations of the product to the existing structure are demanded to qualified
personnel (this qualification does not concerned CoeLux s.r.l.).
Part Number
Serial Number

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NOTE:
Some details concerning turning on the product or its operations in general may depend on
choice made during assembly and /or installation.
• The product is not a toy and should be kept out of the reach of children! Install the product
out of reach of children.
• Be careful not to leave packaging material unattended since it may be a hazardous toy for
children.
• The product must be installed and used only in indoors and dry rooms, not exposed to
humidity and damp.
WARNING:
• Do not install the unit in dirty (dusty) rooms where gas, vapours or dust are or may be
found. Explosion risk!
• Do not cover the system with thermal insulation materials: In particular, the
distance between each product surface and any insulating material present in the ceiling
must exceed 76 mm (3 in) to maintain UL certification.
• The product must not be exposed to extreme temperatures, high vibrations or strong
mechanical stress.
• If safe operations are not deemed possible, the product may be put out of service and any
incorrect handling should be prevented. Expert supervisor should be requested. The correct
working of the system is no longer considered possible when:
- the product is visibly damaged;
- the product does not operate or operate incorrectly (blinking light, smoke or odour
exhaust, audible crackling, product or surrounding surface decolouration);
- the product was stored in unfavourable conditions;
- the product is worn or has been damaged by transport.
• For further questions, please contact CoeLux S.r.l. (see the last page of this manual).
2.5.1 OPERATIONS TO BE AVOIDED
• Altering the unit or its parts, even partially, if not first expressly agreed (writing
authorization) with the manufacturer; the manufacturer is not liable for any consequences
derived from unauthorized changes of the product operated by costumer and/or installer
and/or other subjects. Moreover product alterations also null and void warranty and
certifications;
• Opening the case before cutting off power.
• Performing improper or hazardous operations.
• Obstructing ventilation or heat dissipation slots.

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• Using flammable liquids near the unit.
• Installation or repairs done by unqualified personnel.
• Walking over, hanging on or leaning on the system during all phases of installation.
• Turning on and off repeatedly the system into a period of time of 30 seconds.

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3QUALIFICATIONS OF THE OPERATORS
Logo
Meaning
Function
Generic worker.
Operator without specific skills, only able to
perform simple tasks following instructions
provided by qualified technicians.
Lifting and handling vehicle driver.
Operator qualified to use vehicles for lifting and
handling material (strictly following the
manufacturer's instructions), according to current
laws in the user's country of the unit.
Mechanical technician.
Qualified technician, able to assemble and operate
the unit, to work on mechanical parts for
adjustments, maintenance and necessary repairs.
Not authorised to work on live electrical systems.
Electrical technician.
Qualified technician able to operate the unit,
assigned to perform all electrical adjustments,
maintenance and repairs. This person is qualified
to work on live cabinets and shunt boxes.
Qualified technician or operator.
Technician qualified by CoeLux s.r.l. to perform
complex operations, in special situations or, in any
case, those agreed with the user. According to the
situation, this individual has mechanical and / or
electrical and / or electronic skills.
Tab. 2 Qualifications of the operators
NOTE:
Several positions indicated in the table can be held by a single person following adequate training.
Please note that “OPERATOR” means the individual assigned to assembly, install and clean the
unit.
“QUALIFIED PERSONNEL" or "QUALIFIED OPERATOR” mean those individuals who have attended
specialised courses, training, etc. and have experience with unit installation, operations,
maintenance, repairs and transport.
“EXPOSED PERSON” means a person whose presence in any area inside and/or near the unit
constitutes a risk to his safety, health or security.

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4TRANSPORTATION, MOVEMENT AND STORAGE
4.1 PACKAGING AND TRANSPORT
The unit is shipped adequately protected and packaged in a wooden crate.
Some of the accessories parts can be placed in carton boxes in order to be protected, to facilitate
the transport and to avoid their dispersal.
Due to the particular fragility of some parts, handle packages with care when loading/unloading
from the transport vehicle and during handling.
For this reason the performance of these operations must only be entrusted to trained and
competent staff, such as crane and fork-lift truck operators.
NOTE:
Drawings and instructions that accompany the unit are and remain the exclusive intellectual
property of CoeLux s.r.l., who maintains all rights, prohibits reproduction and the simple
disclosure to third parties, even if only partial.
4.1.1 UNPACKING
NOTE:
Only start unpacking after having completed the cleaning procedure (see paragraph 5.2.1
CLEANING PROCEDURE).
Given the fragility of the content, always work with the utmost care.
1 Make sure the delivered material corresponds to that indicated in the shipping documents.
Immediately contact CoeLux S.r.l. in the event of missing parts or irregularities.
2 For every box, free the various parts from the packaging.
3 Make a careful and scrupulous general inspection to identify any damages suffered by unit
parts during transport. For damages, immediately notify the shipping agent and
manufacturer in writing; do not continue unpacking until authorised by CoeLux s.r.l.
4 Proceed with the mounting phase as indicated in Chapter 7.
5 Recover all packaging material and dispose according to current regulations.

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4.2 MOVEMENT OF THE PARTS
Some product parts weigh more than 25 kg and may require the use of lifting devices for them
lift and movement.
Given the fragility of some parts, always work with the utmost care.
The operator should use adequate personal protection equipment (P.P.E.) such as gloves,
protective shoes, etc.
4.3 STORAGE
Store the product in a closed room, protected from the weather, with the following
environmental characteristics:
- Temperature between -20 °C and +50 °C.
- Relative humidity less than 30% at 40 °C and 90% at 20 °C and, in any case, non-condensing.
- Atmosphere with clean air, without acids, corrosive gases, salts, etc.
The unit must be carefully protected against dust and direct sunlight using an adequate protective
cover and protected against potential accidental collisions.

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5PRE-INSTALLATION
CAUTION !
All activities tied to assembly, installation and mounting the CoeLux® 45 SQUARE and structural
elements must be performed referring to current pertinent regulations and standards. Fixing the
CoeLux® 45 SQUARE to the existing structure is responsibility of the installer.
5.1 TOOLS NOT SUPPLIED BUT NECESSARY FOR INSTALLATION
The following table provides a list of the tools required for CoeLux® 45 SQUARE installation but
not supplied in the assembly kit.
Equipment
Quantity
Note
Figure
Percussion drill.
1
With bits for cement,
reinforced cement and
metal.
Power screwdriver.
At least 1 per
operator.
With inserts for 8 mm
nuts and bolts (star
screw head also).
Suction cups to handle
mirrors
2
Vacuum cleaner.
1

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Electrical socket
adapters.
PPE (Personal
protection equipment)
One per operator.
Helmet, sling, goggles,
shoes, gloves, etc.
Always follow the
regulations in force in
the country of
installation.
Ladders meeting
current standards.
At least 2.
Height > 3.5 m
Screwdrivers, scissors,
knives, wrenches,
hammers
Open-ended, ring,
ratchet and socket
spanners.
1 set.
Specifically 8 mm.
Allen keys.
1 set.
Specifically 4 and 5
mm.

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Livella, laser.
1
Measuring tape.
1
Electrical extension
cord.
At least 1.
Tripolar, length 25 m.
Electrical tape.
At least 1.
Black.
Spray paint.
1
Matt black.
Flashlight.
1

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Sunglasses,
category 3 or 4.
1
Folding gazebo(if
necessary: refer to
Chapter 5).
1
Minimum dimensions
5 x 4 m
Dark Box support.
At least 6.
See chapter
7 ASSEMBLY.
Tab. 3 Necessary tools but not supplied

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5.2 INITIAL CLEANING
For best CoeLux® 45 SQUARE results, guarantee a high level of cleanliness for all product parts.
CoeLux® 45 SQUARE must be assembled in an indoor environment, not exposed to weather, clean
and dry.
WARNING:
Avoid installing CoeLux® 45 SQUARE in poorly clean rooms because product functionality may be
compromise. During assembly and installation follow cleaning procedure exposed below.
Even during assembly, avoiding the contamination of each component is essential since, for
example, dust deposits on internal surfaces, dirt on the CoeLux® panel or above optical
components, may not guarantee maximum product performance. Regular cleaning is essential to
maintain device performance (see paragraph 10 MAINTENANCE).
5.2.1 CLEANING PROCEDURE
A cleaning procedure with a specific kit supplied with the product is provided to promote this
(cleaning kit no. 38-00002-01). The kit is made up of:
-No. 6 polyethylene cloths (5 x 4) to create a clean room for assembly,
-No. 1 spray bottle containing a specific dust remover,
-No. 2 pairs of cotton gloves and
-No. 15 cotton cloths to handle and clean optical parts,
-No. 1 bottle of Vetril® ONLY to be used to clean the CoeLux® panel.
The procedure is described below:
1 Before assembling, create holes in the ceiling or walls to anchor the support sub-structure
(Paragraph 11.1);
2 Clean the assembly room floor;
3 Remove dust and clean the floor: Spray the specific dust remover in the room to create a
clean room, wait about 10 minutes, vacuum the floor and repeat this procedure 2 –3 times
(according to the prior level of cleanliness);
4 Lay to 5 x 4 m polyethylene cloths (one above the other) to cover the assembly floor portions
(floor coverings or pads should be placed UNDER these polyethylene cloths).
5 Hang 4 polyethylene cloths on the room walls or ceiling to create a clean room; join them to
the floor cloths leaving one side open to introduce parts;
6 Spray dust remover in the clean room.
7 Assemble the dark-box inside the clean room.

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NOTE:
Crates should be opened and dark-box parts cleaned outside the clean room. If the room ceiling
is too high and the walls too wide to secure the 4 sides of the clean room, use, for example, a
gazebo as a support frame for the walls.
If several devices are to be mounted, the polyethylene cloths must be removed after one box is
fully assembled and the clean room recreated with new cloths, repeating the entire cleaning
procedure.
5.2.1.1 COMPONENT CLEANING
All unit components must be cleaned immediately before assembly.
All optical parts must be handled with care. Removing dirt is a delicate operations that must be
performed with skill to have positive effects while not ruining optical surfaces.
We recommend starting blandly, proceeding with more decisive and aggressive work until the
contamination is removed.
WARNING:
Incorrect cleaning could cause irreparable scratches on optical surfaces.
If the surface is ruined, interrupt assembly and contact CoeLux S.r.l. to request a replacement.
After assembly, remove any visible dirt from all internal metallic parts, LED projector optical
output and ventilation slots.
5.2.1.2 CLEANING MIRRORS AND THE COELUX® PANEL
Both mirrors and the CoeLux® panel are supplied by CoeLux S.r.l. in a specific package.
When cleaning these components, surfaces should not come into contact with fingers or sewn
glove edges.
WARNING:
These surfaces should always be handled with the cotton gloves.
Before assembling each mirror: after unpacking, analyse mirror surface and proceed as indicated
in figure 3. The detailed procedure is reported in paragraph 11.3.
Before assembling the CoeLux® panel and previously mounted frame (paragraph 7 ASSEMBLY),
remove the protective film from both sides and clean the surfaces in two phases:
- Phase 1 (wet): Clean with a cotton cloth and Vetril® (both provided within the cleaning kit)
wetting the entire surface.
- Phase 2 (dry): before the Vetril® evaporates, wipe with a dry cotton cloth to remove all liquid
and dry the surface. After this operation, wipe with a “dry” cloth before installing the
CoeLux® panel. Several cotton cloths are required for this phase (provided within the
cleaning kit).

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Fig. 3 Flow chart analysis and extraordinary cleaning procedure of mirrors

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6INSTALLATION
6.1 PERMITTED APPLICATIONS
CoeLux® 45 SQUARE is a furnishing accessory to be recessed in the false wall and was designed
for indoor installation, where the minimum ceiling height is 2.700 mm (106.3 inches). Unless
otherwise the recommended final height of the mirror in the false ceiling is at least 2.290 (90.2
inches).
CAUTION !
CoeLux® 45 SQUARE is not suited for outdoor installation exposed to the elements wheatear or
in places that not comply requirements reported in table 1.
WARNING:
The minimum permitted false ceiling height must be verified for each country of installation.
Qualified personnel must assess the use of CoeLux® 45 SQUARE in environment subject to special
regulations (subways, tunnels, etc.). Contact CoeLux S.r.l. for information on each specific project.
6.2 SPACE PLANNING
CoeLux® 45 SQUARE lights space much differently than traditional lighting, imitating an always
sunny window. Before installation, identify the place where the main light beam is directed since
the light direction cannot be changed afterward.
For correct product use, pay attention on artificial lighting compatibility with natural lighting in
the room (due to any windows, skylights, etc.).
When planning CoeLux® 45 SQUARE installation, a false wall trap door is required (with lock) and
relevant crawl space to permit maintenance (see paragraph 8 ENCUMBRANCE, CONNECTIONS
AND CHECKS).
6.3 GENERAL MOUNTING INSTRUCTIONS
CoeLux® 45 SQUARE is made up of a box element (called box and made up of flat steel panels
hardened at the edges) about 2.5 m3, three mirrors (two into the box and one outside), a LED
light source and a CoeLux® panel. The structure must be secured to the wall by a system made
up of a sub-structure, on which the CoeLux® 45 SQUARE will rest.
CoeLux® 45 SQUARE assembly, lifting, mounting and operating procedures must follow the
instructions in the present guide. Those procedures must comply relevant installations
regulations and current safety and health regulations in the country of installation.
CAUTION !
Only qualified personnel by CoeLux S.r.l. may assemble, handle and operate the equipment. The
warranty is null and void and CoeLux s.r.l. is not liable in case of damages due to the inobservance
of the previous prescription. Qualified personnel chosen by installer and under his responsibility
must make fixing of CoeLux® 45 SQUARE to the existing structure.