INSTRUCTIONS DSF640 LED FLOOD LIGHT READ THOROUGHLY BEFORE INSTALLING OVERVIEW This product was designed from the ground up to be the most efficient and reliable LED flood lighting product on the market. Please read and understand all installation instruction prior to installing. Should you have any questions, do not hesitate to contact your local agent or Carolina High Mast for clarification. UNPACKING The DSF640 ships preassembled in one shipping package. The package is designed to minimize risk of damage to the luminaire during shipping and handling. It is recommended that the DSF is not removed from the packaging unless it is to be immediately mounted on the support structure. Each package contains an exterior label that identifies the wattage and lighting distribution. In pre-aimed lighting systems, each package also uniquely identifies the appropriate tower and cross arm location. WARNING: Removing the fixture from the packaging and setting on the ground could damage the glass or exterior finish. Care should be taken to protect the unit if it is to be removed from the packaging and not immediately bolted to the support structure. c. B. INSTALLATION A. TRUNION ORIENTATION The DSF can be utilized in one of three different trunion orientations. The luminaire ships from the factory in the ‘Trunion Down’ orientation. To achieve another trunion orientation, remove the aiming bolts (M6) and loosen the main trunion bolts on the side of the fixture housing (M8). Rotate the trunion to the desired orientation and reinstall the trunion aiming bolts in the threaded holes of the fixture housing that be align for the desired application. The aiming bolts are designed to be installed 180 degrees from each other. a. TRUNION DOWN ORIENTATION The DSF is typically mounted with the trunion below the luminaire. This mounting orientation is typical of the HID luminaires the DSF is designed to replace. b. TRUNION UP ORIENTATION The DSF can be mounted with the trunion above the luminaire with the fixture body below the mounting location. This orientation is useful when utilizing the DSF640 on a CHM lowering device system or when replacing certain existing HID installations. C. TRUNION OUT ORIENTATION The DSF can be mounted to a vertical surface such as a building wall with the trunion horizontal to the ground. This orientation makes mounting to vertical surfaces easier. MOUNTING The DSF640 flood light is provided with a heavy duty mounting trunion. The mounting trunion has clearance for a ¾” main attachment bolt. Raise the luminaire into position and attach the main ¾” trunion bolt. Snug tight the main bolt to hold the luminaire in place. The luminaire shall be adjusted to the proper left-right aiming angle by rotating the luminaire on the main trunion bolt. Once the proper left-right aiming angle has been achieved, tighten the main trunion bolt to 80-90 ft*lb of torque. NOTE: Refer to aiming instructions for additional details on proper aiming procedure. WIRING Make all connections in accordance with the National Electric Code and any applicable local code requirements. a. WIRING TO EXTERNAL JUNCTION BOX OR WIRE WAY The power cable should be routed to external wire way or junction box that is within 24” of the fixture mounting location. A weatherproof cord grip shall be utilized at the junction location to prevent ingress of water into the junction box/wire way. The loose end of the DSF power cable shall be connected to incoming power in accordance with local and national electric code requirements. WARNING: In a L-N-G system, ensure the system neutral is connected to the incoming white wire only. G is exclusively reserved for electrical ground and B is always hot (Line). b. WIRING WITH OPTIONAL BRAD HARRISON STYLE CONNECTOR With this option, the fixture power tail is pre-wired in the factory with a 3 pole, weatherproof connector system designed to connect to the CHM pre-wired sports lighting system. Simply connect the fixture connection to the power plug at the luminaire location on the crossarm. c. 0-10V DIMMING CONNECTION The DSF comes with a secondary 2 conductor power cable for dimming control of the luminaire. From the factory, the dimming cable is sealed with a The included installation instructions are not to be considered to cover all details. General best practice and safety precautions should be taken when working with electrical equipment such as this. Should there be any uncertainty about the guidelines contained herein, Carolina High Mast or an Carolina High Mast representative should be contacted immediately for further guidance. Document Revision 06/10/14 INSTRUCTIONS DSF640 LED FLOOD LIGHT d. weatherproof seal cap. If dimming is to be utilized, cut off the weaterproof cap and strip back the cables. Route the dimming wires in accordance with B.a and connect to incoming control wires. NOTE: The seal cap on the dimming cable shall not be removed unless the 0-10V function shall be utilized and connected in accordance with these instructions. 347V AND 480V SYSTEMS For fixtures optioned with the T3 or T4 option, a 750VA Toroidal transformer will be factory integrated into the luminaire to step down incoming power to 277V. The enclosure will include a dedicated weatherproof cord grip for incoming power and outgoing power to the luminaire. The wiring from the transformer to the luminaire will be factory assembled and shall not be modified in the field. The incoming power wires will include a field ready butt splice joint. Route the incoming power via a 16/3” SO cable through the cord grip and connect incoming power to the supplied butt splice joints. Once wiring is complete, ensure the cable grip is properly tightened on the incoming power cable. WARNING: In a L-N-G system, ensure the system neutral is connected to the incoming white wire only. G is exclusively reserved for electrical ground and B is always hot (Line). 18/2 POWER CABLE FOR 010VDC CONTROL IF NEEDED. In the pre-aimed configuration, both the horizontal and vertical aiming indicators with be marked with the appropriate aiming settings. Adjust the luminaire until the aiming mark aligns with the aiming bolt. IF the fixture is not pre-aimed from the factory, follow the aiming steps below. NOTE: The vertical aiming bolts are Allen head socket bolts. The hardware is METRIC sizing. Use of incorrectly sized hardware to tighten these bolts could damage the fasteners. To properly aim the DSF640, the mounting structure shall have mounting holes in accordance with the CHM mounting detail. Contact CHM Industries for the drill pattern necessary to support the DSF640. If purchasing mounting structure from CHM, the plates will be factory drilled to accommodate the DSF. AIMING VIA INCLINOMETER RECOMMENDED METHOD IN LIEU OF TARGET AIMING 1. 2. 3. 4. 5. LED DRIVERS, FACTORY WIRED. 6. 18/3 POWER CABLE FOR INCOMING 120V-277V POWER AIMING PREPARATION Prior to aiming of the flood lighting fixtures, it is critical to ensure the proper distributions are located in the appropriate location on the support structure. The label on the underside will show the complete part number including the light distribution. Distributions are in degrees and include 15D, 20D, 30D, 45D and 60D beam angles. Distributions should be matched to the supplied aiming array illustrating the fixture array, aiming angles and specific distribution. The pole and crossarms must be braced so that they are both LEVEL (parallel) with the ground. Each floodlight is attached to the crossarm(s) so that the glass lens is LEVEL (parallel) with the ground. Loosen the (4) aiming bolts (2 per side) and (2) main trunion bolts. The aiming bolts are M6 and the main trunion bolt is M8. An inclinometer is positioned on the glass lens perpendicular to the crossarm. The down angle adjustment that is indicated in the square boxes of the fixture arrangement and aiming schedule is made. The bolts that attach the trunnion to floodlight housing are tightened. Match mark the location of the aiming bolt (Sharpie permanent marker will work here) and the trunion aiming angle so that the fixture can be repositioned to the correct location. The vertical aiming bolts and main trunion bolt are then loosened and the floodlight is rotated back to its original horizontal (level) position in preparation for Left or Right adjustment. Retighten the bolts. The inclinometer is positioned on the glass lens parallel to the crossarm. The crossarm attachment bolts are loosened, the Left or Right angle adjustment is made, and the bolt is retightened. Finally, the trunnion/fixture bolts are loosened and the floodlight is rotated to its final vertical position (against the reposition stop). Make sure that the stop is not bent by rapid movement during rotation. Securely tighten all bolts and screws. AIMING VIA AIMING BOLTS 1. 2. 3. Mount the luminaire to the mounting structure. Loosen the (4) aiming bolts (2 per side) and (2) main trunion bolts. The aiming bolts are M6 and the main trunion bolt is M8. Adjust the vertical aiming angle until the aiming bolt align with the appropriate down angle as shown on the aiming array provided by CHM. Loosen the main ¾” attachment bolt. Rotate the fixture left or right to the appropriate angle as shown on the aiming array provided by CHM. Once the proper left-right aiming angle has been achieved, tighten the main trunion bolt to 80-90 ft*lb of torque. DEGREE AIMING The DSF is provided with a horizontal and vertical aiming indicator. These aiming indicators can be used for general aiming indication. NOTE: If precision aiming is required, the target aiming process should be followed. Contact CHM for detailed target aiming instructions. The included installation instructions are not to be considered to cover all details. General best practice and safety precautions should be taken when working with electrical equipment such as this. Should there be any uncertainty about the guidelines contained herein, Carolina High Mast or an Carolina High Mast representative should be contacted immediately for further guidance. Document Revision 06/10/14 INSTRUCTIONS DSF640 LED FLOOD LIGHT 3. 4. VERTICAL AIMING BOLT ALIGNS WITH AIMING ANGLE STAMPED ON ADDITIONAL SAFETY NOTES 1. 2. 3. HOLE FOR MAIN TRUNION BOLT 4. SLOT FOR AIMING BOLT Align the visor so that the clamp bolt is on the bottom side of the light emitting surface. Torque the main visor clamp bolt until the visor is tightly affixed to the LED housing. 5. High Intensity Discharge (HID) lamps contain mercury and should be disposed of in accordance with Federal, State and Local codes. Allowed the luminaire to cool to ambient temperature prior to handling. This luminaire is a high wattage, high voltage piece of equipment. There is a RISK OF ELECTRICAL SHOCK when working on this product. Installation, service and maintenance should be conducted by properly trained personnel only. Do not fuse the incoming ground or neutral line to the luminaire; this can cause electrical shock and death. Do not modify or retrofit this product without the express authorization of CHM. CLEANING AND MAINTENANCE HORIZONTAL AIMING BOLT ALIGNS WITH AIMING ANGLE LABELED ON THE TRUNION EXTERNAL VISOR The DSF is designed to be as maintenance free as possible over the typical design life of an LED luminaire. While the DSF includes impressive levels of ingress protection, buildup of environmental contaminants can reduce overall fixture efficiency. 1. LED HOUSING. VISOR CLAMPS AROUND THIS FEATURE. 2. EXTERNAL VISOR ASSEMBLY VISOR CLAMP BOLT The external visor for the DSF640 is designed to minimize up lighting, lower property line spill and reduce direct view of the light sources from off-axis viewing angles. The external visor ships separate of the DSF luminaire to be installed in the field. The external visor consists of a light absorbing top visor and clamp ring that is designed to clamp around the black housing of the LED array. 1. 2. 3. The glass on the optical assembly is high strength tempered glass. It can be cleaned with a standard cleaning solution like Windex. It is strongly recommended that a microfiber cloth is used to clean the glass to avoid scratches in the surface. The perforated body of the DSF is designed to allow the airflow necessary to cool the LED array to extremely low and stable operating conditions. In certain extreme environments like arena applications where dirt is utilized (rodeo, motorcross, monster truck, etc), extreme levels of dirt can build up on luminaires. In these applications, it is suggested that the DSF is inspected for dirt build up on the cooling apparatus. Should there exist an excessive level of dirt built up, it is suggested that the luminaire be blown out with compressed air. This is not unique to the DSF and is also suggested for standard HID and competitive LED products. The DSF is covered by a 5 year complete replacement warranty (longer terms available) and will not require any internal maintenance over that term. Once the fixture is installed on the mounting structure, remove the external visor from the shipping package. Slide the visor ring around the LED housing until the visor bracket is making contact with the gray fixture housing body. The included installation instructions are not to be considered to cover all details. General best practice and safety precautions should be taken when working with electrical equipment such as this. Should there be any uncertainty about the guidelines contained herein, Carolina High Mast or an Carolina High Mast representative should be contacted immediately for further guidance. Document Revision 06/10/14