650486-001 INSTRUCTION SHEET
Installation Instructions for Appleton™ Code•Master™ LED Luminaire
FOR PROPER AND SAFE INSTALLATION OF THIS PRODUCT, PLEASE READ THE FOLLOWING INSTRUCTIONS.
Product Safety
Signal Words Defined
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous
situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury. NOTICE is used to address practices not related to physical injury.
Safety Instructions for Complete Luminaire
WARNING:
• Do not open or remove the luminaire with the circuit energized.
• Do not remove or replace fuse when luminaire is energized.
• To avoid burning hands, allow luminaire to cool down prior to maintenance.
• Do not use this luminaire on ungrounded systems. Failure to ground the luminaire can result in an electric shock,
which may be fatal.
• Before installation, ensure that the unit complies with the hazardous area classication. Refer to luminaire nameplate,
located on exterior of housing body, for suitability in specic hazardous locations.
• Do not open when explosive atmospheres are present.
• Beware of electrostatic charges. Use a moist cloth to non-metallic parts.
• Supply wires are to be rated for minimum 90°C.
CAUTION:
• Do not look directly at the LEDs when energized.
• Disconnect the luminaire from the supply circuit before opening to reduce the risk of ignition in hazardous atmospheres.
• Do not replace any component in hazardous area. Move the luminaire into the area known to be non-hazardous.
• It is necessary that the globe and all conduit plugs are tightly secured and all luminaire ttings (mounting hood and optic) are tightly
secured to the LED housing to prevent water and dust entry. The optic should be cleaned periodically to maintain lighting efciency.
NOTICE:
• Do not touch the LEDs; touching could leave oily deposits, causing hot spots and potential premature failure.
• This luminaire is designed for and should be installed with hazardous locations wiring method required in accordance with the
National Electrical Code®, Canadian Electrical Code and all applicable local codes.
• This product must be installed in accordance with the applicable installation code by a person familiar with the construction and
operation of the product and hazards involved.
• Do not use this equipment for anything other than its intended use.
Applications/Intended Use
• Marine and wet locations: Apply a corrosion-inhibiting grease, such as petroleum or soap-thickened mineral oils, in 3 lines,
spaced approximately 120 degrees apart, perpendicular to the threads. Tighten all unused close-up plugs to a torque of
3.8 Nm min. 5.5 Nm max.
• Areas where ammable gases and vapors are present under conditions dened by the ratings below.
• Ideal for use in chemical and petrochemical plants, such as manufacturers of plastic, paints and thinners; in reneries and other
process areas where ignitable vapors, dust, moisture, and corrosive elements may be present.
Appleton • 1.800.621.1506 • www.appletonelec.com 650486-001 Rev. A 10/18/18 • Page 1 of 14
Agency Ratings
• Class I, Division 1, Groups B (pendant and stanchion mount only), C, D
• Class II, Division 1, Groups E, F, G
• Class II, Division 2, Groups F, G
• Class III
• Class I, Zone 1, Group IIB & H2
• Type 3R, 4X
• IP66, IP67
• Suitable for wet locations
• Marine outside type (salt water) for US application only
NOTES:
Refer to product nameplate, located on the exterior of the housing body for details.
650486-001 Rev. A 10/18/18 • Page 2 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Luminaire Dimensions
FIGURE 1: CODE•MASTER LED LUMINAIRE DIMENSIONS
FIGURE 2: FIXTURE/ACCESSORY WEIGHTS
650486-001 Rev. A 10/18/18 • Page 3 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Mounting Hood Dimensions and Installation
WARNING: Both the Pendant (P/N: CAP75B) and the 25º Stanchion (P/N: CAS150B) mounting hoods must have a Group B
approved sealing tting of the appropriate trade size installed within two inches of the hood. Any manufacturer’s
Group B approved sealing tting may be used. Follow the manufacturer’s sealing tting instructions for proper
seal installation.
Pendant:
CAP-75, CAP-100, CAP-75B
Dimensions:
FIGURE 3: PENDANT HOOD DETAILS
Installation:
1. Remove connection block from pendant hood by loosening the two mounting screws.
2. Thread pendant hood onto the conduit and tighten locking set screw.
3. Connect GROUND wire to GREEN screw in pendant hood.
4. Connect supply wires to appropriate wires on connection block. Note that the BLACK wire is LINE and the WHITE wire is
COMMON/NEUTRAL.
5. Reinsert connection block into the pendant hood and tighten securely.
6. Thread luminaire onto the pendant hood; the electrical contacts will automatically engage. Ensure that the luminaire is threaded
tightly and tighten the locking set screw.
650486-001 Rev. A 10/18/18 • Page 4 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Ceiling:
CAC-75, CAC-100
Dimensions:
FIGURE 4: CEILING HOOD DETAILS
Installation:
1. Remove connection block from ceiling hood by loosening the two mounting screws.
2. Bolt the ceiling hood to a supported surface using the four external mounting holes.
3. Connect GROUND wire to GREEN screw in ceiling hood.
4. Connect supply wires to appropriate wires on connection block. Note that the BLACK wire is LINE and the WHITE wire is
COMMON/NEUTRAL.
5. Reinsert connection block into the ceiling hood and tighten securely.
6. Thread luminaire onto the ceiling hood; the electrical contacts will automatically engage. Ensure that the luminaire is threaded
tightly and tighten the locking set screw.
650486-001 Rev. A 10/18/18 • Page 5 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Wall Bracket:
CALB-75, CALB-100
Dimensions:
FIGURE 5: WALL BRACKET HOOD DETAILS
Installation:
1. Remove connection block from wall bracket hood by loosening the two mounting screws.
2. Bolt the wall bracket hood to a supported surface using the four external mounting holes.
3. Connect GROUND wire to GREEN screw in wall bracket hood.
4. Connect supply wires to appropriate wires on connection block. Note that the BLACK wire is LINE and the WHITE wire is
COMMON/NEUTRAL.
5. Reinsert connection block into the wall bracket hood and tighten securely.
6. Thread luminaire onto the wall bracket hood; the electrical contacts will automatically engage. Ensure that the luminaire is threaded
tightly and tighten the locking set screw.
650486-001 Rev. A 10/18/18 • Page 6 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
25° Stanchion:
CAS-150, CAS-150B
Dimensions:
FIGURE 6: 25° STANCHION HOOD DETAILS
Installation:
1. Remove connection block from stanchion hood by loosening the two mounting screws.
2. Thread stanchion onto the conduit and tighten locking set screw.
3. Connect GROUND wire to GREEN screw in stanchion hood.
4. Connect supply wires to appropriate wires on connection block. Note that the BLACK wire is LINE and the WHITE wire is
COMMON/NEUTRAL.
5. Reinsert connection block into the stanchion hood and tighten securely.
6. Thread luminaire onto the stanchion hood; the electrical contacts will automatically engage. Ensure that the luminaire is threaded
tightly and tighten the locking set screw
650486-001 Rev. A 10/18/18 • Page 7 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Wiring Diagrams:
FIGURE 7: WIRING DIAGRAM WITHOUT FUSE
FIGURE 8: WIRING DIAGRAM WITH FUSE
650486-001 Rev. A 10/18/18 • Page 8 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
LED Driver Replacement
FIGURE 9: LED DRIVER REPLACEMENT
CAUTION: Disconnect xture from supply circuit before opening to service. Keep tightly closed when in operation.
NOTICE: Only replace LED Driver with a factory supplied component. Using LED Driver from another source could cause damage
to the LED Array or other xture components.
1. To replace LED arrays, after disconnecting power, Loosen the round head locking screw in the globe ring until it clears the pry bars
in the LED Driver mounting base.
2. Unthread globe ring assembly. A screwdriver inserted through the slots in globe ring and operated against the pry bars will assist
in removal. NOTE: Do not hold glass globe to unthread globe ring assembly, as this may loosen the globe locking ring. If globe
locking ring is accidentally loosened, it must be retightened. Loosen set screw in globe locking ring, tighten globe locking ring, then
retighten set screw.
3. After removing globe assembly, disengage connector with Blue and Red leads from LED. Remove screw holding the wire tie
clamping the wires running to LED driver.
4. Slide the wires through hole in casting and unscrew heat sink from LED driver mounting base. This will expose the LED driver.
5. Disconnect black/white wires running to LED driver and remove screws holding LED driver in place.
6. Replace LED driver with the screws that held the old driver in place and tighten securely.
7. Remake wire connections (black/white wires) and reassemble xture in reverse order of disassembly.
8. See wiring diagrams for wiring details.
650486-001 Rev. A 10/18/18 • Page 9 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Optional Fuse Kit
FIGURE 10: FUSE KIT INSTALLATION
WARNING: Do not open or remove luminaire with the circuit energized.
WARNING: Do not install fuse kit in marine applications.
1. Loosen the round head locking screw in the globe ring until it clears the pry bars in the LED heatsink mounting base.
2. Unthread globe ring assembly. A screwdriver inserted through the slots in globe ring and operated against the pry bars will assist
in removal. NOTE: Do not hold glass globe to unthread globe ring assembly, as this may loosen the globe locking ring. If globe
locking ring is accidentally loosened, it must be retightened. Loosen set screw in globe locking ring, tighten globe locking ring, then
retighten set screw.
3. Unscrew heat sink from LED driver mounting base. This will expose the LED driver and the fuse mounting area.
4. Use supplied screws to mount fuse holder to LED driver mounting base.
5. Cut BLACK lead to LED driver and splice in the leads from the fuse holder with wire nuts.
6. Reassemble in the reverse order of disassembly, ensuring that globe ring, heat sink, and housing are tightly secured.
650486-001 Rev. A 10/18/18 • Page 10 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Safety Cable Installation
FIGURE 11: SAFETY CABLE INSTALLATION
NOTE: The xture housing has two drilled and tapped holes (3/4-10) on sides of each xture to attach safety cable.
1. Install threaded insert into holes in sides of housing, with notches in the tting to outside of housing. Be sure to screw inserts all the
way to the bottom of tapped holes.
2. Slide lock washer over (1) 1/2" bolt, then slide bolt through loop in one end of cable/clamp assembly. Thread nut onto bolt until it
hits cable. Screw bolt into threaded insert in housing nger tight. Loop cable around a secure object (e.g., large pipe/beam).
3. Repeat bolt/lock washer/nut installation through cable on other side of xture.
4. Tighten bolts holding the cable at each end to a minimum of 10-foot pounds of torque.
650486-001 Rev. A 10/18/18 • Page 11 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Trunnion Mounting
FIGURE 12: TRUNNION HOOD INSTALLATION
NOTE: The xture housing has two drilled and tapped holes (3/4-10) on the sides of each xture to attach the trunnion bracket.
1. Install threaded insert into holes in the sides of housing, with the notches in the tting to the outside of the housing. Be sure to
screw inserts all the way to the bottom of tapped holes.
2. Line up holes in the sides of trunnion bracket with the installed threaded inserts.
3. Slide supplied 1/2" bolt through a lock washer, through hole in trunnion bracket and into threaded insert. Do not tighten completely.
Repeat process on other end of trunnion bracket.
4. Locate the mounting holes at the top of trunnion bracket and use appropriate hardware (not supplied) to mount xture securely.
5. Mount luminaire directly to the wall or any structural support member that can handle the weight of the xture in accordance with
local building code and all other code applications. Be sure to consider weight of the xture (43 lbs. with bracket) and provide
adequate support at the mounting point.
6. After aiming the xture in the desired position, tighten the (2) 1/2" bolts securely to maintain selected angle.
650486-001 Rev. A 10/18/18 • Page 12 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Optional Wire Guard
FIGURE 13: WIRE GUARD INSTALLATION
1. Line up loops at ends of wire guard legs with three holes in lens ring.
2. Insert screws into holes and hand tighten rmly into place.
650486-001 Rev. A 10/18/18 • Page 13 of 14Appleton • 1.800.621.1506 • www.appletonelec.com
Except as expressly provided by Appleton Grp, LLC (Appleton), Appleton products are intended for ultimate purchase by industrial users and for operation by persons trained and experienced in the use and maintenance of this equipment
and not for consumers or consumer use. Appleton warranties DO NOT extend to, and no reseller is authorized to extend Appleton’s warranties to any consumer.
While every precaution has been taken to ensure accuracy and completeness in this manual, Appleton Grp, LLC. assumes no responsibility, and disclaims all liability for damages resulting from use of this information or for any errors or
omissions. Specications are subject to change without notice. The Appleton and Emerson logos are registered in the U.S. Patent and Trademark Ofce. All other product or service names are the property of their registered owners.
©2017 Appleton Grp, LLC. All rights reserved.
650486-001 Rev. A 10/18/18 • Page 14 of 14
Loading...