www.osramamericas.com
®
LEDstixx Lighting System
For Shallow and Deep Set Back Cooler Cases - 3 Series
INSTALLATION GUIDE
This installation guide outlines step-by-step instructions for
proper mechanical and electrical installation of OSRAM
LEDstixx® Lighting System products and power supplies. This
document should never be considered a substitute for any
provision of a regulation or state and/or legal code.
WARNING: ONLY QUALIFIED PERSONNEL SHOULD PERFORM INSTALLATION
TO AVOID ELECTRICAL SHOCK OR COMPONENT DAMAGE, DISCONNECT POWER BEFORE ATTEMPTING INSTALLATION OF THE POWER SUPPLIES
AND/OR MODULES.
Failure to install the power supplies and/or LED modules in accordance with the National Electric Code (NEC), all applicable Federal, State and local electric
codes as well as the specific Underwriters Laboratories (UL) safety standards for the installation, location and application may cause serious personal injury,
death, property damage and/or product malfunction.
These instructions are guidelines for installation of LED modules and power supplies. Installation requirements may vary depending on the application. Licensed
electricians should provide all installation services for connection for both primary and secondary (input/output) of the power supplies.
“WARNING”: Risk of fire or electric shock. Luminaires, wiring, ballasts, or other electrical parts may be damaged when drilling for installation of reflector kit
hardware. Check for enclosed wiring and components.
“WARNING”: Risk of fire or electric shock. Reflector/retrofit kit installation requires knowledge of fluorescent lighting luminaires electrical systems. If not qualified,
do not attempt installation. Contact a qualified electrician.
“WARNING”: Risk of fire or electric shock. Install this kit only in luminaires that have the construction features and dimensions shown in the “product diagram”.
“WARNING”: To prevent wiring damage or abrasion, do not expose wiring to edges of sheet metal or other sharp objects.
Identification and Warnings of Safety Hazards
In accordance with ANSI Z535.4-2002 the following system of identifying the severity of the hazards associated with the products is used:
“DANGER”: Imminently hazardous situation which, if not avoided, will result in death or serious injury.
“WARNING”: Potentially hazardous situation which, if not avoided, could result in death or serious injury.
“CAUTION”: Potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage. Also used to alert against unsafe
practices.
IGNORING A HAZARD WILL VOID ANY WARRANTY
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LED348
1.0 MECHANICAL INSTRUCTIONS
1.1 Tools Required:




Philips and/or Flat Blade Screwdrivers
Needle Nose Pliers
Wire Cutters/Strippers
Hex Keys
1.2 Case Configurations:
Label
Case Configuration
CM
Center Mullion
EM(L)
Left End Mullion
EM(R)
Right End Mullion
PS
Pow er Supply
System Wattages
2
Item Numbers
Please see Product
Information Bulletin LED192
for the list for complete item
numbers.



Tape Measure
Eye Protection
Work Gloves
1.3 Case Identification
If the installation is a replacement of an existing fluorescent system, it is recommended that the case manufacturer be identified. Case Brand
Labels are generally displayed near the top of the case, at the Frame Header and should identify the manufacturer. Obtaining this information
may be beneficial as many case manufacturers offer specific installation, repair and replacement documents online. This installation guide is
written such that any removal or access instructions are dictated by the manufacturer’s provisions and to instruct the installer concerning any
product specific instructions once access and provision are made.
WARNING – Turn off and disconnect the power to the case and the ballast before proceeding with the installation.
1.4 LEDstixx Installation Instructions:
1.4.1
LEDstixx ‘shallow’ setback uses one Mounting Bracket per unit mounted on the back side of the mullion, inside the cooler.
Deep uses 2 mounting brackets
1.4.2 Secure Mounting Bracket with the base against and parallel to the mullion using two self-drilling screws positioned between the two
ribs on the base of the bracket (Figure 2).
Note:
Figure 2 shows the winged bracket available for mounting 4”setback units.
Figure 3 shows the mounting clip available for mounting 10”setback units.
Position screws vertically as far apart as possible with the screws located between case shelves allowing for easy access with a
cordless screwdriver. Carefully move product on the shelf to provide sufficient clearance to work.
Note: (Applies to shallow setback LEDstixx only)
Figure 2 (Shallow Setback)
a. Center unit mounting bracket is bidirectional and features two leading wings
on both sides of bracket. (Shallow
Setback)
b. End unit mounting bracket features a
leading wing that must be positioned such
that the wing leads to the center of the
case door. Please refer to Figure 4.
(Shallow Setback)
(Provided w/ Unit)
(Provided w/ unit)
Mounting
Brackets
Figure 3 (Deep Setback)
(Deep Setback)
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Figure 4
1.4.3 Position connector side of LEDstixx up or down depending on the direction of preferred power routing. Please refer to section 1.5.6.
1.4.4 Press the LEDstixx unit into the Mounting Bracket “U” channel, between the two end caps of the LEDstixx unit, with the lens
portion facing inside the cooler (Figure 4). Verify that the LEDstixx unit snaps tightly into the “U” channel of the Mounting Bracket.
1.4.5 Connect the Positive (Red) wire from the LEDstixx wire harness with the 24VDC wire coming from the OT75 power supply wire
harness. Connect the Negative (Black) wire from the LEDstixx wire harness with the negative from the wire harness coming from the
OT75 power supply. Note the green and white wires in the LEDstixx wire harness are for dimming system applications. Properly cap
off these wires if not being used. (See Figure 14 for Wiring Diagram)
1.4.6 Secure the cable to the mullion/cooler wall. Slide the cable cover over the end of the LEDstixx to cover the wire harness entry
to the mullion
1.4.7 Energize.
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1.5 Power Supply Installation Instructions:
1.5.1
To gain access to the existing ballast, the contact Plate Retainer (Zipper Strip) and Contact Plate must first be removed from
the mullion. (Fig. 5 & 6)
Fig. 5
1.5.2
1.5.3
The Contact Plate Retainers and Contact Plates should be placed in a location where they will not be damaged.
Disconnect the line and load side connectors from the ballast. Unscrew the ballast mounting screws and remove the ballast
from the mullion. (Fig. 7 & 8)
Fig. 7
1.5.4
Fig. 8
The connectors attached to the remaining load and line side wiring harness must be cut off and the wires stripped to 0.47” or
as required by splice connectors used.
Fig. 9
5
Fig. 6
Fig. 10
1.5.5
Install the new Optotronic OT75 power supply and re-use the previous ballast’s screws to secure the OT75 into the existing
mounting holes. (Fig. 11)
Fig. 11
Note:
1.
2.
Depending on the size of the ballast removed, it may become necessary to drill an additional mounting
hole to match the foot print of the OT75.
The AC ground wire from the line side wiring must be firmly bonded to the case of the OT75.
1.5.6
DC load side wiring from the power supply should never run in parallel to AC wiring. If AC line side wiring feeds from the top of
the cooler, the LEDstixx module should be mounted such that the power supply’s DC output wiring will feed the LEDstixx
module at the bottom of the cooler. Conversely, should AC line side wiring feed from the cooler’s bottom channel, then the
power supply’s output wiring must feed from the top of the cooler. The orientation of the LEDstixx receiving power from the
power supply must be the same throughout the case. Please refer to Figure 14.
1.5.7
To identify the color coding of wiring feeding the tombstones in an adjacent mullion, access must be gained similarly to that
mentioned in 1.5.1. However, complete removal of the contact plate is not necessary. Partial “peel” back as shown in fig. 11 &
12 should be considered.
Fig. 12
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Fig. 13
2.0
ELECTRICAL INSTRUCTIONS
2.1 General Instructions:
If additional wiring becomes necessary, it is the responsibility of the installer to provide this wiring and ensure that the wiring meets all
applicable Class 2 requirements as pertains to the installation.
Pay attention to standard Electrostatic Discharge (ESD) precautions when installing the system.
2.2 Wiring Diagrams:
Fig. 14 – Basic Wiring Diagram
LEDstixx Wiring
Blue (Negative)
Red (Positive)
Green & White- Dimming Leads
Fig. 14.1 – Wiring Diagram with dimming option
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Notes:
1.
2.
3.0
The wiring diagram is purely diagrammatic. The power supply DC output wiring must be kept separate from any AC wiring. Therefore the
orientation of the LEDstixx and subsequent wiring schemes to maintain this separation must be determined in the field.
Contractor is responsible for providing any additional wiring necessary to feed from the output of the power supply to the “Input
Connector” noted in the diagram. Contractor is responsible for the connection of said “Input Connector” to additional wiring.
RELATED INFORMATION
3.1 List of Applicable and Related Documents:
 Document LED192R2 – LEDstixx Vertical Refrigeration- 3 Series Product Information Bulletin (PIB)
 Document ECS050 – Power Supply Product Information Bulletin (PIB)
 Document LED093 – Electrostatic Discharge Protection for LED Systems
 Document LED157 - LEDstixx® Lighting System Warranty
3.2 Responsibilities and Considerations
3.2.1
Owner/User Responsibilities:
It is the responsibility of the contractor, installer, purchaser, owner, and user to install, maintain, and operate LEDstixx
and components in such a manner as to comply with all state and local laws, ordinances, regulation, ad the American
National Standards Institutes Safety Code.
3.2.2
Installation Configurations:
When planning a LEDSTIXX installation, OSRAM suggests doing the following:
 Consult and Electrical Inspector to approve all wiring plans.
 Refer to local and state codes for installation compliance.
 Consult OSRAM Customer Service Center @ 1-800-LIGHTBULB.
LED348
OSRAM is a registered trademark of OSRAM GMbH.
Specifications subject to change without notice
© 2013 OSRAM SYLVANIA Inc. 5/13
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