INSTALLATION INSTRUCTIONS COVE 1
Thank you for purchasing the Compose Indirect Lighting System PATENT PENDING 2
1 COMPOSE COVE SYSTEM PARTS LIST CORNERS A B EXTRUDED COVES & MOUNTING HARDWARE C D E F * G H I LED MODULES J K L A 90 Degree Corner - Outside CPCF-XXKXXW-CO G Alignment Spline (Included with Compose Cove) 700-50556 B 90 Degree Corner - Inside CPCF-XXKXXW-CI H End Cap Flat Front 700-50579-L/R C Compose Cove Knife Edge - 8 700-50485K30-08 I End Cap Knife Edge 700-50578-L/R D Compose Cove Flat Front - 8 CMP-EXT-08 J LED Module - Available in 12, 18 & 48 lengths. CMPX-XXK-XXW E Power Entry Cover Plate 700-50581 K Power Entry Cable Straight CP-PE-120 F Allen Key (Included with Compose Cove) 780-50572 L Power Entry Cable Right Angle 685-50532-RT *The Allen key is.0035 (7/2000 ) & 1-5/16 Overall Length **The straight extrusions are supplied with one spline and screws installed at the factory. 3
1 CONSIDERATIONS BEFORE INSTALLATION APPLICATION This is a dry location product only. Do not place in wet or exterior applications. TEMPERATURE This LED module requires temperature conditions within the range of -20 C (Min) and 50 C (Max) CUSTOMER SUPPORT If you have questions after reading this information or would like our advice on your project, call us before working with any product from i2systems. i2systems Technical Support is available from 9 a.m. to 5 p.m. EST by phone at 1.860.567.0708 or email at support@i2systems.com. A FREE COPY OF THIS INSTALLATION GUIDE IS AVAILABLE ONLINE AT www.i2systems.com 4
1 CONSIDERATIONS BEFORE INSTALLATION ELECTRICAL WARNINGS This is a dry location product only. Do not place in wet or exterior applications. Read and understand the LED module installation instructions and safety labels before you begin your installation. Turn off the power before installing or servicing the LED module and/or connecting or disconnecting individual units. Follow all national and local electrical and construction codes and regulations. The 120-277VAC feed must include an internal separate ground wire connected back to the electrical panel. Comply with the maximum voltage rating of the LED module. Operate the LED module within the specified temperature ranges. Avoid making live connections, also known as hot swapping. Grounded armored cable must be attached to the extruded cove. 5
1 CONSIDERATIONS BEFORE INSTALLATION Verify the input current and LED module wattage before beginning the installation. Determine the watts per foot for the i2systems LED module you are installing. There is a label on each LED module which outlines the acceptable input voltages between 120 and 277VAC as well as the watts per foot at 50/60Hz. The AC input voltage and the wattage of the LED module will determine the run length. www.i2systems.com SURFACE MOUNT LUMINAIRE 120-277 VAC 50/60 HZ DANGER-RISK OF ELECTRIC SHOCK-DISCONNECT POWER BEFORE SERVICING-DRY LOCATIONS ONLY. MIN 80C SUPPLY CONDUCTORS. DANGER-RISQUE DE CHOC-COUPER L'ALIMENTATION AVANT L'ENTRETIEN-POUR EMPLACEMENTS SECS SEULEMENT. PRECAUCION-RIESGO DE CHOQUE ELECTRICO-DESCONECTAR LA ENERGIA ANTES DEL SERVICIO-LUGARES SECOS EXCLUSIVAMENTE. NO USER SERVICEABLE PARTS. DRY LOCATIONS ONLY. SUITABLE FOR UNDER-CABINET MOUNT. DO NOT DISCONNECT UNDER LOAD. E474071 CAUTION Exceeding the input voltage or acceptable LED module run lengths will result in damage to the LED module and may pose a serious safety hazard. 6
1 INSTALLATION REQUIREMENTS INSTALLATION WALL MUST HAVE CONTINUOUS BLOCKING BEHIND DRYWALL FOR THE ENTIRE LENGTH OF THE EXTRUDED COVE. WALL FOR INSTALLATION SHOULD BE +/- 1/16 TRUE PLUMB ACROSS 48 OF THE PLANAR SURFACE. WE RECOMMEND A 7A BREAKER FOR EACH LIGHTING CIRCUIT. FOR PROJECTS USING A CORNER, THE CORNER SHOULD BE INSTALLED BEFORE THE STRAIGHT SECTIONS. WORK AWAY FROM THE CORNERS AND FIELD CUT STRAIGHT SECTIONS AS NEEDED. THIS LED MODULE SHOULD BE MOUNTED HORI- ZONTALLY WITH LIGHT BEAMING ABOVE, ONLY. A RIGHT ANGLE POWER ENTRY CABLE IS REQUIRED WHEN ANY ROW OF LIGHTS WILL BE BROKEN INTO MULTIPLE SECTIONS. 7
2 INSTALLATION PROCEDURE 2.1 For proper performance, the LED module should be installed no less than 6 from ceiling 6 2.2 LED modules need to be installed from RIGHT to left. Therefore, power entry must be provided on the right side of the run. MODULE 2 MODULE 1 2.3 INSTALL ALL CORNERS & EXTRUDED COVES AS FOLLOWS: 3.1 Install all corners. 4.1 Install all full length extruded coves. 5.3 Install extruded coves that have been cut to length. 8
3 INSTALLATION OF CORNERS 3.1 Confirm wall has continuous blocking and is straight/plumb. Wall for installation MUST be +/- 1/16 true plumb across 48 of the planar surface. If your installation is utilizing inside or outside corners, the corners must be installed first in order to ensure proper fit to field dimensions. As opposed to the straight runs, the corners are not able to be modified in the field. 3.2 For any corner that will have power connected, cut armored cable to length and install in factory drilled hole in extrusion using supplied armored cable connector. 9
3 INSTALLATION OF CORNERS 3.3 Drill 1 hole in wall for cable access so that cable can be connected to building wiring. As opposed to drilling a hole, the blocking may be interrupted in the sections where you will be bringing power into tray. 3.4 Place the corner unit so that the side and bottom flanges are firmly against the corner of the wall and secure with screws so that the flanges are smooth against the wall. Use drywall screws, typ #8 x 1 5/8 sharp point drywall screw, to attach corner. The corner is now complete and you are ready to install the straight runs. 10
4 INSTALLATION OF STRAIGHT EXTRUDED COVE 4.1 Confirm wall has continuous blocking and is straight/plumb. Wall for installation MUST be +/- 1/16 true plumb across 48 of the planar surface. 4.2 Extruded coves come with protective covers in place. The protective covers are used to prevent debris and other building materials from damaging the snap features in the extruded cove. If the extruded coves need to be cut or drilled, the protective covers can be removed for the modification and replaced when complete. Extruded coves can be cut in the field for the best fit. These cuts are best made using an appropriately sized sliding compound saw fitted with a carbide tipped blade designed for cutting non-ferrous metals. 4.3 If your installation requires a power entry in a straight run, pre-drill power entry hole as required. Power entry hole should be drilled to a 1/2 diameter so that it falls between LED modules and have an armored cable connector attached prior to installation to wall. 0.50 Diameter 11
4 INSTALLATION OF STRAIGHT EXTRUDED COVE 4.4 Drill a 1 hole in wall for cable access so that cable can be connected to building wiring. As opposed to drilling a hole, the blocking may be interrupted in the sections where you will be bringing power into tray. 4.5 Place the extruded cove so that the rear side and bottom flanges are firmly against the wall and the end is flush with the end of the extruded cove. Secure with screws* so that the flanges are smooth against the wall. < 18 CAUTION: Screws should be spaced no less than 18 apart. A screw should be fastened within 1 of the end of the cove. *Use drywall screws, typ #8 x 1 5/8 sharp point drywall screw, to attach the extruded cove. 12
4 INSTALLATION OF STRAIGHT EXTRUDED COVE 4.6 Loosen the supplied alignment spline set screws, do not remove, and slide spline so that half of the spline is in the previously installed extruded cove and the other half is in the newly installed extruded cove. For your convenience, a.035 hex key has been included in the hardware. CAUTION: Do not over-tighten these screws. Apply only enough force to lock the components together. Over tightening the screws can deform the exposed face of the cove. 4.7 Attach successive coves as outlined in 4.5 and 4.6 to complete installation. CAUTION: There should be no gap between the extruded coves. After completing this step, all of the corners and extruded coves should be installed. NO GAP THERE SHOULD BE NO GAP BETWEEN THE EXTRUDED COVES 13
5 TAPING AND SPACKLING 5.1 The rear and bottom flanges should be skim coated with Durabond 90 and sanded so that the transitions between the extrusions and drywall are smooth and not visible. CAUTION: Ensure that compound does not fall into the extruded cove as it could prevent proper mounting of the LED module. The basic installation represents a tight hairline seam. For installations requiring a true seamless aesthetic, the contractor can fill any seams with Bondo Lightweight Filler and sand for a true seamless appearance. 5.2 Ensure the extrusions are clean and free of oil and any debris. Make sure all protective covers are in place. Prime and paint outer exposed surfaces. THERE SHOULD BE NO GAP BETWEEN THE EXTRUDED COVES 14
6 INSTALLATION OF THE LED MODULE 6.1 Once paint has dried, remove protective covers from trays and discard. Locate the power entry point and plug power cable into the right side of the LED module. CAUTION: The cable can only enter the tray between the LED modules. 6.2 Plug the cable from this LED module into the next LED module to be installed and place the LED module into the tray. Continue until all LED modules have been plugged in and placed into the trays. Note: The cable in the LED modules can be extended a maximum of 3 by pulling the cable slowly from the light for ease of installation. However, in order to avoid any dark spots, ensure that the gap between the LED modules does not exceed 0.5. 15
6 INSTALLATION OF THE LED MODULE 6.3 Once all LED modules are positioned in the trays and wired, snap each into place by pressing thumbs under tray and fingers on the top of the front of the LED module. Squeeze until the LED module snaps into place. PUSH DOWN 6.4 If the LED module needs to be moved within the tray, it can be slid along the length of the tray by gently pushing in the desired direction. NOTE: Ensure that the gap between the LED modules does not exceed 0.5. 6.5 The power entry cover plate is now ready to snap over cable. Using the same method as snapping in the module, place protective plate over power entry cable. 16
7 REMOVAL OF THE LED MODULE 7.1 If the LED module needs to be removed, press down on the back of the end caps so that the back of the LED module rotates down and the light releases from the extruded cove. PUSH DOWN 7.2 Ensure power is off, and then unplug and remove the LED module. 17
8 WIRING & ELECTRICAL Exceeding the input voltage or acceptable LED module run lengths will result in damage to the LED module and may pose a serious safety hazard. 18
WARNING Ensure that main power supply is off before installing or wiring a LED module. Risk of fire or electric shock, installation requires knowledge of luminaire electrical systems. System must be installed by a qualified electrician according to local and national codes for proper installation. Risk of fire or electric shock. Luminaire wiring and electrical parts may be damaged when drilling. To prevent wiring damage or abrasion, do not expose wiring to edges of sheet metal or other sharp objects. Only use LED modules with voltage for which it is rated. Do not exceed the specified input voltage and current. LED modules have line voltage risk of shock and no user serviceable parts. Do not attempt to open. Do not use a LED module if the lens, housing, or power cables are damaged. Do not hot swap LED modules. Ensure that power to the series is off before connecting or disconnecting individual LED modules. Contractor is responsible for adequately reinforcing walls and/or ceilings to support luminaire weight. i2systems accepts no responsibility for inadequately reinforced walls and/or ceilings. Do not make or alter any open holes in an enclosure of wiring or electrical components during installation. Wear proper safety equipment and follow appropriate safety precautions. Connect to a properly grounded branch circuit protected by a circuit breaker or fuse Always use i2systems and/or i2systems-recommended components. For use on systems with voltages greater than the maximum rated voltage, use a safety agency approved, step-down power supply to convert the higher voltage to a voltage within the specified operating range of the LED module. 19
FCC NOTES The hardware device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for a Class A device, pursuant to Part 15 of the FCC regulations. These limits are designed to provide reasonable protection against harmful interference in a residential or commercial installation. However, there is no guarantee that interference will not occur in a particular installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed or used in accordance with the instructions, may cause harmful interference to radio communications. If this equipment does cause harmful interference to radio of television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: 1. Reorient or relocate the receiving antenna; 2. Increase the separation between the equipment and the receiver; 3. Connect the equipment to an outlet on a circuit different from that to which the receiver is connected; 4. Consult the dealer or an experienced radio/tv technician for help. Any changes or modifications not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment. Where shielded interface cables have been provided with the product or specified accessories elsewhere defined to be used with the installation of the product, they must be used in order to ensure compliance with FCC regulations. INSTALLATION/THERMALS Once installed, monitor the LED module case temperature. The LED module case temperature should not exceed 50 C at worst case ambient. Should the case temperature exceed the max rating of 50 C, do one or more of the following: reduce the ambient temperature, heatsink the LED module, increase the airflow or volume of air around the LED module, or remove the LED module and install a lower power LED module. Do not install the light LED module where any liquid will come in contact with the module or the wiring. Do not install the light LED module where it will sit in any liquid or where liquid will collect, pool or puddle. LED module is suitable for indoor dry locations only. It is recommended that the light LED module remain in its original container until it is ready to be installed. 20
092-04313 REV-A 21