LumaFilm® Light Emitter Installation Instructions (Supplement) These Instructions are intended to be used as an installation guide to be completed by, or under the direction of a qualified electricians in accordance with all national and local electrical codes as well as construction standards. IMPORTANT – Please review prior to installation Safety Notes: •
Always ensure the power is securely off prior to and during installation. •
LumaFilm Light Emitters [Sheets] (referred to as “LumaFilm” or “LumaFilm Sheets”) must be powered by a UL recognized or listed Class 2, constant current, LED power supply. Please refer to the LumaFilm Power Supply Selection Guide (found later in these installation instructions) for the correct power supply to use. Please contact the Heilux Technical Team with any questions (techsupport@heilux.com). •
LumaFilm is not intended to be submerged in water. •
LumaFilm Sheets are low voltage electrical devices that can be damaged by electrostatic discharge. Always follow good industry practices for handling semiconductor devices when handling LumaFilm Sheets. Handling Instructions: •
Avoid creasing or repeated bending of LumaFilm Sheets. •
LumaFilm Sheets are flexible. Do not bend LumaFilm Sheets to a diameter of less than one inch (25.4mm). •
Do not scrape or use excessive rubbing force. •
Clean LumaFilm with the power off by gently wiping with a soft damp cloth. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 1 Pg. 3 Pg. 5 Pg. 7 Pg. 10 Pg. 11 Pg. 13 Pg. 19 Index Attachment Instructions for LumaFilm Light Emitters IDC Connector Installation Notes Wiring Instructions for LumaFilm Light Emitters Tiling Instructions for Multiple LumaFilm Light Emitters Modifying the Size of LumaFilm Light Emitters LumaFilm Power Supply Selection Guide Troubleshooting Heilux, LLC – 952.944.9859 or techsupport@heilux.com 2 Attachment Instructions for LumaFilm Light Emitters LumaFilm can be attached to a wide range of surfaces using mechanical fasteners, adhesive products, or a combination of both. Due to its unique low heat generation, no heat sink is required. •
Mechanical fastening can be used on any surface, including drywall, rough surfaces, metal, plastic and smooth surfaces. Mechanical fasteners are recommended for surfaces that are rough, unpainted or dirty. o Use the factory supplied holes in the LumaFilm Sheet. o Use mechanical fasteners that are 0.125” (3.175mm) in diameter. o Use at least four No. 6 type A sheet metal screws of a length that a screw, when installed in the mounting holes, penetrates the mounting surface by no less than .75” (19.05mm). Additional fasteners may be inserted through carefully drilled holes made in non-­‐electrically active areas of the LumaFilm Sheet. Non-­‐electrically active areas are the cross-­‐
hatched areas of the LumaFilm Sheet. o Place a suitably sized Nylon washer between the head of the fastener and the LumaFilm Sheet. For bolts and blind rivets, also place a washer (of similar metal) between the nut or the expanded shaft of the rivet. o Avoid spinning the washer against the LumaFilm Sheet when tightening the fastener. •
Adhesive Transfer Tape (3M: 467MP or VHB 5952 are the only adhesives tapes currently approved for use with LumaFilm). These can be used in areas that are smooth and/or have a finished surface. Ensure that the surface to which the adhesive tape will be applied is clean and dry. o Use 3M 467MP on metal, plastic and painted smooth surfaces. o Apply a strip to each long edge and the center of each LumaFilm Sheet. o Pull back a short length of the adhesive tape liner from each of the three strips of adhesive tape. o Position the LumaFilm Sheet and use the exposed adhesive tape to tack the LumaFilm Sheet in place. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 3 o Holding the free end of the LumaFilm Sheet with one hand, carefully lower the LumaFilm Sheet onto the support material. At the same time pull the liner from the adhesive tape. o Use a clean foam paint roller or your hand to apply firm pressure to the LumaFilm Sheet without exerting shear force on the LEDs. o For rough surfaces, use 3M VHB 5952 adhesive foam tape using the preceding instructions. •
For the mounting and connection of the power supply, please refer to the power supply manufacturer’s installation instructions. Heilux does not accept responsibility for the incorrect mounting and/or connection of the power supply. Incorrect mounting and/or connecting of the power supply may void the LumaFilm warranty. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 4 IDC Connector Installation Notes Items required for ease of installation: 1. One AVX IDC insertion tool bit P/N 9176 (as shown to the right) 2. 18AWG 7 to 19 stranded wire Steps 1. Place the 18AWG wire over the IDC connector (as shown below) 2. Align AVX IDC insertion tool bit over the wire and connector. The wire will fit through the notches on the tool. 3. Firmly press the tool until it bottoms out on the substrate. The connector will pierce through the wire hosing and complete the connection. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 5 4. Remove AVX IDC insertion tool bit by lifting straight up away from wire and IDC connector. 5. Trim off excess wire with a standard wire cutter. Removing wire. Should a situation arise where removal of a wire is necessary, please follow this simple instruction: Place the tip of a small flathead screwdriver in the middle of the IDC connector (as shown below) and pull up on the wire. Be sure to trim off the pierced portion of the wire before re-­‐inserting. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 6 Wiring Instructions for LumaFilm Light Emitters LumaFilm’s unique circuit design allows for a range of wiring options. A single LumaFilm Sheet to a power supply and multiple LumaFilm Sheets with power supply that can be combined are illustrated in schematics 1, 2 and 3 below. •
Always follow the manufacturers instructions for wiring of power supplies and dimmers. •
You may wire more than LumaFilm Sheet together as long as the total power is at or below Class 2 voltage and power limitations. •
For larger lit areas, use multiple power supplies. •
Never combine LumaFilm Sheets together with a single supply that is greater than 100 Watts. •
Always ensure that the power supply is disconnected from the branch circuit whenever wiring LumaFilm Sheets or power supplies. Single LumaFilm Light Emitter (Sheet) w/Power Supply Schematic 1 Heilux, LLC – 952.944.9859 or techsupport@heilux.com 7 Multiple LumaFilm Light Emitters (Sheets) w/Power Supply Schematic 2 Schematic 3 Heilux, LLC – 952.944.9859 or techsupport@heilux.com 8 Wires connecting LumaFilm Sheets to additional LumaFilm Sheets (sheet-­‐to-­‐sheet wires) or light sheets to the low voltage (output) side of the Class 2 power supply that are intended to be concealed or routed through building members, or not concealed but with a total exposed length not exceeding 3m (10ft) must be type CL2X, 18 AWG, (as listed in Article 725 of the NEC). Class 2 wiring that is not concealed and has a total length exceeding 3m (10ft) must be type SPT2 or better, 18 AWG. Insulation on the low voltage conductors must be rated at or higher than the AC supply voltage. DC output conductors and AC input conductors must be physically separated. Connection to the power supply output and AC input must be made in separate junction boxes. The output wires from the power supply and the wires connected to the light sheets may be made without a junction box via a luminaire connector such as the WAGO 873 Series Lumi-­‐Nut. Power supplies maybe remotely mounted from the actual location of the LumaFilm Sheets. To determine the maximum distance, please contact the power supply manufacturer for recommendation. LumaFilm Sheets can be connected to standard dimmers, please contact the dimmer manufacturer for the appropriate dimmer, connection instructions and recommendations for use. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 9 Tiling Instructions for Multiple LumaFilm Light Emitters (Sheets) LumaFilm Sheets can be joined together to make a single sheet. Heilux recommends the use of 3M 8401 splicing tape or equivalent tape applied to the back of all adjoining sheets. Ensure that the surface to which the LumaFilm Sheet is placed on during the taping process is soft to avoid damage to the LEDs. Schematic 4 Heilux, LLC – 952.944.9859 or techsupport@heilux.com 10 Modifying the Size of LumaFilm Light Emitters LumaFilm is designed for ease of installation in the field. LumaFilm Sheets maybe trimmed by the installer to the appropriate size in the field to provide for such ease. LumaFilm Sheet sizes may vary based on the customer’s needs, and any field trimming should follow these simple cutting/trimming guidelines: Prior to trimming any LumaFilm Sheet, you MUST understand your power supply needs. See LumaFilm Power Supply Selection Guide (page 13 of these instructions). For LumaFilm Sheets (Standard pitch of 27mm) with 5 rows or less, note that only rows may be cut or trimmed off. DO NOT CUT or TRIM COLUMNS. Trimming or cutting must take place between the LEDs only. For LumaFilm Sheets (Standard pitch of 27mm) with more than 5 rows, one can field modified by cutting or trimming either the rows, columns, or both. Trimming or cutting must take place between the LEDs only. For LumaFilm Sheets (High Output pitch of 16mm) only rows may be cut or trimmed off. DO NOT CUT or TRIM COLUMNS. NOTE: Rows are defined as having the bus bar circuit running along the length. Columns are defined as perpendicular to Rows. Schematic 5 Heilux, LLC – 952.944.9859 or techsupport@heilux.com 11 Trimming/Cutting Photos: Trimming -­‐ Columns Carefully cut along the middle of the selected bus bar (as shown in the picture to the left). Once the LumaFilm Sheet is cut, a completed electrical circuit maybe made by soldering a wire to the connection pad. Trimming -­‐ Rows Carefully cut between the LEDs (as shown in the picture to the left). Keep at least 0.125”/3.175mm from either LED. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 12 LumaFilm Power Supply Selection Guide The instructions below are used to determine the Class 2 Power Supply specifications for a specific LumaFilm project. LumaFilm Light Emitters run on DC current. Do not plug into an AC wall outlet. Damage will occur to the LumaFilm Light Emitters (Sheets) and LEDs will be destroyed. All electrical wiring must be installed by or under the direction of a qualified electrician in accordance with all national and local electrical codes as well as construction standards. Three steps are required to determine the correct power supply: 1. Establish the current requirements 2. Determine operating voltage 3. Calculate power consumption Schematic 6 Step 1: Establish Current Requirements (mA): The standard current for LumaFilm is 20mA per row. Operating current = 20mA times the number of rows The maximum operating current is 30mA times the number of rows Heilux, LLC – 952.944.9859 or techsupport@heilux.com 13 Example: A 9.5” x 22” LumaFilm Light Emitter has 20 rows. Each 9.5” x 22” LumaFilm Light Emitter requires a standard current of 400mA (20mA * 20 rows = 400mA). If the maximum current of 30mA per row is desired, a 9.5” x 22” LumaFilm Light Emitter that has 20 rows will require a maximum current of 600mA (30mA * 20 rows = 600mA). When connecting (tiling) LumaFilm Sheets together the same standard current requirements apply. Examples: 30 rows (1 full sheet and 1 half sheet) at 20mA = 600mA 40 rows (2 full sheets) at 20mA = 800mA Step 2: Determine the Voltage Required (Volts dc): The voltage required for LumaFilm is based on the number of LEDs per row and the choice of current. • Current at 10ma requires 2.7 volts dc per LED • Current at 20mA requires 3.0 volts dc per LED • Current at 30mA requires 3.2 volts dc per LED Example: Using the standard 9.5” x 22” LumaFilm Light Emitter, there are 9 LEDs per row. Choosing to run at 20mA results in the following voltage requirement: Volts dc = 9 LEDs per row times 3.0 volts per LED = 27 volts dc Step 3: Calculating Power Consumption (Watts): Once the current and voltage have been established, the power consumption (as measured in Watts) can be determined using the standard equation: Power = Current times Voltage (Current needs to be in Amps. Divide the current in mA by 1000) Watts = mA/1000m times Volts dc Example: Two 9.5” x 22” LumaFilm Light Emitters contain 40 rows and will be run at 20mA. Current: 40 times 20mA = 800mA Voltage requirement for 9 LEDs per row at 20mA is 27 volts dc Power consumption: 800mA/1000A times 27 volts dc = 21.6 Watts Heilux, LLC – 952.944.9859 or techsupport@heilux.com 14 Select a UL rated Class 2 Power Supply with a power rating greater than 21.6W that will provide a constant of 800mA in a voltage range of 27V or greater. Note: Class 2 power supplies must operate at 100W or less and have a maximum voltage output of 60Vdc or less. If the power supply you select is not adjustable to or available with the calculated current, select the closest to (above or below) the calculated current without exceeding Class two operating conditions or the LumaFilm maximum rating of 30mA per row. WARNING: For applications requiring more than 100 Watts use multiple power supplies connected to separate groups of LumaFilm Sheets. Never connect the output leads of multiple power supplies in parallel to power a larger array of LumaFilm Sheets. Heilux, LLC – 952.944.9859 or techsupport@heilux.com 15 Power Supply Selection Guide
LumaFilm Light Emitter (9.5" x 22")
20 rows of 9 LEDs in series; 180 LEDs per sheet
5000K CCT
Operating current per LED mA:
Minimum voltage required:
Operating current per sheet:
Power (V*A) per sheet:
Average Lumens/Watt:
Operating current per LED mA:
Minimum voltage required:
Operating current per sheet:
Power (V*A) per sheet:
Average Lumens/Watt:
Operating current per LED mA:
Minimum voltage required:
Operating current per sheet:
Power (V*A) per sheet:
Average Lumens/Watt:
10mA
26V
200mA
5.2W
140
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
200mA
400mA
600mA
800mA
1.0A
1.2A
1.4A
1.6A
1.8A
2.0A
2.2A
2.4A
2.6A
2.8A
3.0A
3.2A
3.4A
3.6A
3.8A
5.2W
10.4W
15.6W
20.8W
26.0W
31.2W
36.4W
41.6W
46.8W
52.0W
57.2W
62.4W
67.6W
72.8W
78.0W
83.2W
88.4W
93.6W
98.8W
700
1,400
2,200
2,800
3,600
4,300
5,100
5,800
6,500
7,200
8,000
8,700
8,900
9,500
10,900
11,600
12,300
13,000
13,800
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
5
6
7
8
9
400mA
800mA
1.2A
1.6A
2.0A
2.4A
2.8A
3.2A
3.6A
10.8W
21.6W
32.4W
43.2W
54.0W
64.8W
75.6W
86.4W
97.2W
1,400
2,800
4,200
5,600
7,000
8,400
9,800
11,200
12,600
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
5
600mA
1.2A
1.8A
2.4A
3.0A
17.4W
34.8W
52.2W
69.6W
87.0W
2,100
4,200
6,300
8,400
10,400
20mA
27V
400mA
10.8W
130
30mA
29V
600mA
17.4W
120
Heilux, LLC – 952.944.9859 or techsupport@heilux.com 16 Power Supply Selection Guide
LumaFilm Light Emitter (12" x 24")
24 rows of 12 LEDs in series; 288 LEDs per sheet
5000K CCT
Operating Current per LED mA)
Minimum Voltage required
Operating current per sheet
Power (V*A) per sheet
Average Lumens/Watt:
Operating current per LED mA:
Minimum voltage required:
Operating current per sheet:
Power (V*A) per sheet:
Average Lumens/Watt:
Operating current per LED mA:
Minimum voltage required:
Operating current per sheet:
Power (V*A) per sheet:
Average Lumens/Watt:
10mA
34.8V
240mA
8.35W
140
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
5
6
7
8
9
10
11
12
240mA
480mA
720mA
960mA
1.2A
1.44A
1.68A
1.92A
2.16A
2.4A
2.64A
2.88A
8.35W
16.7W
25.1W
33.4W
41.8W
50.1W
58.5W
66.8W
75.2W
83.5W
91.9W
100W
1,200
2,300
3,500
4,700
5,800
7,000
8,200
9,300
10,500
11,700
12,800
14,000
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
5
6
480mA
960mA
1.44A
1.92A
2.4A
2.78A
17.3W
34.6W
51.8W
69.5W
86.4W
100W
2,250
4,500
6,700
9,000
11,200
13,000
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
720mA
1.44A
2.16A
2.60A
27.6W
55.3W
82.9
100
3,300
6,600
9,900
12,000
20mA
36V
480mA
16.7W
130
30mA
38.4V
720mA
27.6W
120
Heilux, LLC – 952.944.9859 or techsupport@heilux.com 17 Power Supply Selection Guide
LumaFilm Light Emitter (5" x 24")
39 rows of 8 LEDs in series; 312 LEDs per sheet
5000K CCT
Operating Current per LED mA)
Minimum Voltage required
Operating current per sheet
Power (V*A) per sheet
Average Lumens/Watt:
Operating current per LED mA:
Minimum voltage required:
Operating current per sheet:
Power (V*A) per sheet:
Average Lumens/Watt:
Operating current per LED mA:
Minimum voltage required:
Operating current per sheet:
Power (V*A) per sheet:
Average Lumens/Watt:
10mA
23.2V
390mA
9.05W
140
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
5
6
7
8
9
10
11
390mA
780mA
1.17A
1.56A
1.95A
2.34A
2.73A
3.12A
3.51A
3.90A
4.29A
9.05W
18.1W
27.2W
36.2W
45.9W
54.8W
63.3W
72.4W
81.4W
90.5W
99.5W
1,200
2,500
3,800
5,000
6,400
7,700
8,800
10,100
11,400
12,700
13,900
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
4
5
780mA
1.56A
2.34A
3.12A
3.90A
18.7W
37.4W
56.2W
74.9W
93.6W
2,400
4,900
7,300
9,700
12,100
# of Sheets
Current
Power
Lumens
(approx.)
1
2
3
1.17A
2.34A
3.51A
30.0W
60W
90W
3,600
7,200
10,800
20mA
24V
780mA
18.7W
130
30mA
25.6V
1170mA
30.0W
120
Heilux, LLC – 952.944.9859 or techsupport@heilux.com 18 Troubleshooting If a LumaFilm Light Emitter (Sheet) does not illuminate when the power is turned on: 1) Check to ensure all electrical connections have been made and are intact. 2) Check to ensure that the wires from the LumaFilm Sheet to the power supply are correctly connected by polarity. If one section of LEDs on a LumaFilm Light Emitter (Sheet) does not illuminate when the power is turned on it is likely that the circuit to that section of LEDs is damaged. The LumaFilm Light Emitter (Sheet) should be replaced. If a single LED on a LumaFilm Light Emitter (Sheet) does not illuminate when the power is turned on it is likely that the connection between the single LED and the circuit on that particular Light Emitter has been broken or the LED has failed. The overall light output of the system will not be affected significantly. If the LumaFilm Light Emitter is mounted such that the LED is not visible, there is no need to replace the Light Emitter (Sheet). If the LumaFilm Light Emitter is mounted such that the failed LED is visible, then a replacement Light Emitter (Sheet) may be required. Contact for LumaFilm Technical Support: 1.952.944.9859 (tel) techsupport@heilux.com Heilux, LLC 10200 Valley View Road, Ste. 100 Eden Prairie, MN 55344 www.heilux.com LumaFilm is a registered trademark of Heilux, LLC © 2015 Heilux, LLC Heilux, LLC – 952.944.9859 or techsupport@heilux.com lii150617 19