Cold Cathode Installation Instructions |
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Section A
DETERMINING DIMENSIONS & CONSTRUCTING PATTERNS: |
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Section B
MOUNTING THE TRANSFORMER OR BALLAST IN THE CABINET HOUSING: |
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Section C
DETERMINING TRANSFORMER OR BALLAST LOCATIONS & CONDUIT RUNS: |
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Section D
MOUNTING THE TRANSFORMER OR BALLAST ENCLOSURE HOUSING: |
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Section E
PRIMARY WIRING: |
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Section F
DETERMINING LAMPHOLDER LOCATIONS: |
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Section G
INSTALLATION OF LAMPHOLDERS |
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Section H
INSTALLATION OF INTERFEED CONDUIT, GTO CABLE & WIRING CONNECTIONS: |
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1. Begin by taking the exact overall length of the area covered by the cold cathode installation. The dimensions are to be recorded on the plan or elevation drawings, then forwarded to the manufacturer, Square 1 Precision Lighting, Inc. for the preparation of installation instructions, drawings, and the fabrication of the cold cathode lamps.
2. When exact field dimensions cannot be accurately obtained, or when the cold cathode lamps are intended to be a patterned shape or curve, construct and provide the manufacturer, Square 1 Precision Lighting, Inc. with a sample pattern representative of the condition. Construct the pattern by tracing the actual field condition on a 1/8 inch plywood, masonite, or particle board surface. Do not use paper or cardboard. Cut the traced pattern out and verify the cut and fit with the actual field condition. Label each section of the pattern on the pattern and indicate the location on the plans and/or elevation drawings. Forward the patterns and the drawings to the manufacturer, Square 1 Precision Lighting, Inc. for the preparation of installation instructions, drawings and the fabrication of the cold cathode lamps. The patterns along with specific installation instructions will be returned to the installing contractor for use with the installation of the lampholders and the cold cathode lamps. 3. Upon the installing contractor's receipt of the installation instructions, drawings, and patterns, verify the exact field dimension(s) and fit of the pattern with actual job site conditions. Compare actual field dimensions with the dimensions indicated in the cold cathode plan and elevation drawings. All field dimensions are to correspond with the dimensions indicated in the drawings. When actual field dimensions do not correspond with the drawing dimensions, do not continue with the installation. Contact the manufacturer and indicate the discrepancies. |
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1. With the transformer housing positioned in the upright position (removable top up), place the transformer in the cabinet with the high voltage terminals (2) inches, minimum, away from the cabinet housing's wall. Provide a minimum separation of (1 1/2) inches for the high voltage terminal wiring. Place one non-terminal side of the transformer against the side wall of the housing (the transformer housing will provide a heat sink to further heat dissipation and optimize the operation of the transformer).
2. With the transformer positioned properly, mark and drill (1/4) inch holes for the mounting bolts. Remove all metal debris from the cabinet housing. With the bolts, nuts and washers that are provided with transformer, secure the transformer to the housing. Tighten each bolt and nut to secure the transformer from any movement or vibration. When required, mount the neoprene vibration isolation pads between the transformer and the housing. 3. When mounting ballasts, center the ballast within the cabinet housing. With the ballast positioned properly, mark and drill (1/4) inch holes for the mounting bolts. Remove all metal debris from the cabinet housing. With the bolts, nuts and washers that are provided, secure the transformer to the housing. Tighten each bolt and nut to secure the ballast from any movement or vibration. When required, mount the neoprene vibration isolation pads between the transformer and the housing . |
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1. Locate the transformer or ballast and housing in an accessible ventilated location as close to the feed lampholders as construction conditions will permit. The ambient temperature of the mounting location shall not exceed 100"F.
Keep the secondary GTO leads as short as possible and equally distant from each terminating end lampholder. The maximum distance from the transformer or ballast to the terminating lampholder are as follows:
2. Each transformer or ballast housing will have a minimum of (3) conduit connections. They are as follows: a. One primary conduit from the 120VAC source. b. Two secondary conduits from the terminating lampholders. Each conduit proceeds from the transformer to a terminating lampholder. See SECTION J for important installation instructions. 3. Match each transformer or ballast with its proper location. Each transformer or ballast is labeled and the label markings are indicated accordingly on the installation drawings. 4. From the 120VAC dedicated power source and circuit breaker, connect the primary conduit for the transformer directly to the primary side of the transformer or ballast housing. When a local disconnect switch or circuit breaker is not mounted on the transformer or ballast enclosure, connect the primary conduit to the disconnect switch or circuit breaker first, then to the primary side of the transformer or ballast housing. All conduit, fittings and junction boxes shall be suitable and listed for their rated use. |
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| Section D MOUNTING THE TRANSFORMER OR BALLAST ENCLOSURE HOUSING: [See Illustration 14 - Transformer and Housing Detail] [See Illustration 15 - Transformer Wiring Detail] [Refer to Instruction and Installation Drawings] |
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1. With the transformer properly mounted in the enclosure housing, place the enclosure housing in the upright position with the primary side facing the primary feeder conduit and the secondary side facing the high-voltage GTO cable conduits. 2. Secure the transformer and housing to the mounting surface with screw or bolt fasteners using the (1/2) inch spacer blocks. The spacer blocks will provide ventilation to the underside of the enclosure housing and reduce the transmission of vibration to the mounting surface. Position the enclosure housing spacer blocks between the cabinet housing and the mounting surface and place the fasteners through the holes in the spacer block. Secure the enclosure housing to the mounting surface so that each fasting point is capable of supporting the weight of the assembly. The assembly must be supported with two fasteners minimum. Four fasteners are recommended. 3. With the enclosure housing securely mounted in place, connect the primary and secondary conduits. |
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| Section E PRIMARY WIRING: [See Illustration 15 - Transformer Wiring Detail] [Refer to Instruction and Installation Drawings] |
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| 1. With the transformer or ballast enclosure housing securely in place and the primary and secondary conduits connected, verify that 120VAC branch power supply is disconnected at the electrical panel's circuit breaker. Install the primary wiring as indicated in the installation drawings. Connect the primary feed (BLACK wire) from the electrical panel's circuit breaker to the primary side of the local disconnect switch or circuit breaker. Connect the load wire (RED wire) to the load side of the disconnect switch or circuit breaker, then connect the load wire to the primary terminal of the transformer or ballast. 3. Connect the neutral wire (WHITE wire) to the neutral terminal of the transformer or ballast. 4. Connect the ground wire (GREEN wire) to the enclosure housing's ground terminal and properly ground the system. |
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1. All lamp holders shall be located so that the lamps are kept a minimum of (1) inch away from all metal surfaces.
2. All lampholders shall be located according to the dimensions indicated on the Instruction and Installation Drawings or as indicated on the field template. 3. Terminating lampholders are located at the beginning and the end of the cold cathode lamp system(s). Intermediate lampholders are located between individual lamp runs within the system (s). |
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3 Cold Cathode Surface Mounted Terminating Lampholder |
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| 1. Position the lampholders according to the dimensions indicated on the Instruction and Installation Drawings or as indicated on the field template. Position lamp holders accurately maintaining a (1/16) inch maximum tolerance. Any greater tolerance will result in the lamps not fitting into the lampholders. 2. With fasteners suitable for the mounting surface, i.e.: screws or bolts, mount each lampholder securely into position using two fasteners per lampholder. |
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2 Typical Cold Cathode Lighting Diagram
5 Cold Cathode Surface Mounted Interfeed Connection 1O Cold Cathode Recessed Mounted Interfeed Connection] |
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1. For cold cathode lighting systems that contain two or more sections of lamps that are separated from each other, an interfeed connection is required.
2. From the last terminating lampholder and junction box of one section of the system, install one conduit run to the last terminating lampholder and junction box of the second section of the system. Keep the conduit (6) inches away from all other conduits. Install one high voltage GTO cable in the interfeed conduit. Do not use any wire/cable pulling compounds. 3. Connect one end of the GTO cable to the terminal screw inside one terminating lampholder then connect the opposite end to the second terminating lampholder. 4. When using metallic conduit for interfeed connections the conduit must be grounded (bonded) to the transformer enclosure housing. |
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2 Typical Cold Cathode Lighting Diagram
3 Cold Cathode Surface Mounted Terminating Lampholder 6 Cold Cathode Surface Mounted Terminating Lampholder- No Junction Box 8 Cold Cathode Recessed Mounted Terminating Lampholder] |
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1. In systems incorporating junction boxes, as in illustrations 3 & 8, run one conduit from the transformer enclosure to the junction box of each terminating lampholder. Maintain a distance of (6) inches minimum between secondary conduits and all other conduits, as well as other parallel, ferrous structures. Install one GTO cable per conduit only. Use absolutely no wire/cable pulling compounds. Connect the end of the GTO cable to the terminal screw inside the terminating lampholder. Replace the porcelain cover, and nylon cap nut.
2. In systems incorporating no junction box, as in illustration 6, run one conduit from the transformer enclosure to within (3) feet of each terminating lampholder. Maintain a distance of (6) inches minimum between secondary conduits and all other conduits, as well as other parallel, ferrous structures. Install one GTO cable per conduit only. Use absolutely no wire or cable pulling compounds. Attach aluminum flexible conduit to then lampholder end of conduit run. Pass this conduit a small way through the wall surface. Install a nylon flexible conduit connector, slide a length of dielectric carrier tubing (over the GTO) to the connector. The dielectric carrier tubing extends from the nylon connector and passes through the socket cable entry hole. Connect the end of the GTO cable to the terminal screw inside the terminating lampholder. Replace the porcelain cover, and nylon cap nut. 3. In systems incorporating P-K housings, pull GTO through all associated parts, and hex-crimp the spring assembly rivet to the end. Install the GTO strain relief. Retract the GTO so that the spring assembly is properly seated in the glass housing. Secure the GTO conduit (or flexible conduit) directly to the P-K housing. |
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| Copyright 2000, Square 1 Precision Lighting | |||||||||||||