GE Lighting GELT403040CTR-SY, GELT403050CTR-SY, GELT403050CTR-SB, GELT403650CTR-SB, GELT403640CTR-SB Retrofit Installation Manual

imagination at work

GE

Retrofit Installation Guide

Lighting

™

IMMERSION

LED Refrigerated Display Lighting

Vertical Cases
RV40 Series

Center Mullion LED Lights

750 mm (30-inch): GELT403050CTR-SY/-SB (79777/79780), GELT403040CTR-SY/-SB (79783/79786)
900 mm (36-inch): GELT403650CTR-SY/-SB (79795/79798), GELT403640CTR-SY/-SB (79801/79804)

Description Code (Single Unit Product Number / 10-Pack Product Number)

BEFORE YOU BEGIN

Read these instructions completely and carefully.

FOR YOUR SAFETY

Read and observe all CAUTIONS and WARNINGS shown
throughout these instructions.

• Installation to be performed by factory trained service personnel only.
For use inside a commercial refrigeration case with packaged foods only.

•

This device complies with part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference, and (2)
this device must accept any interference received, including interference that may
cause undesired operation.
NOTE: This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequen­cy energy and, if not installed and used in accordance with the instruction manual, may
cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.

This Class [A] RFLD complies with the Canadian standard ICES-003. Ce DEFR de la classe
[A] est conforme à la NMB-003 du Canada.

WARNING / AVERTISSMENT

Risk of electrical shock. Disconnect power before servicing or installing product.
/ Risque de choc électrique. Couper le courant avant de réparer ou installer le produit.

LED DRIVER COMPATIBILITY

This system is compatible with the GEPS4000NCMUL-SY
LED Driver. Please refer to the separate LED driver installation

guide for appropriate wiring connections.

CAUTION / ATTENTION

Risk of injury. While performing installations described, gloves, safety
glasses or goggles should be worn. / Risque de blessure. Lors de l'exécution
des installations décrites, des gants, des lunettes de sécurité ou des lunettes
de protection doivent être portées.

A. Use this unit only in the manner intended by the manufacturer. If you

have any questions, contact the manufacturer.

B. Before servicing or cleaning unit, switch power off at the service panel

and follow appropriate lock out /tag out safety procedures.

PREPARE ELECTRICAL WIRING

Electrical Requirements

•

The power supply must be supplied with 100-240 VAC,

50/60 Hz., and connected to an individual properly
grounded
circuit breaker or time delay fuse.
Wiring must be 2 wire with ground and rated for

•

• Do not overload driver, follow installation instructions
for the GEPS4000NCMUL-SY.

• Ensure that all connection points are sealed for damp
location using the appropriate method per the NEC or
local electrical code.

branch circuit, protected by a 15 or 20 ampere

75°C (167°F).

1

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Remove Existing Lighting Components

Tools Required

4

5

1

Wire stripper/cutter

2

Tape measure

3

Screwdriver

4

Cordless drill

5

Hammer

6

2.8mm (7/64-inch) drill bit

7

Center punch

6

• For retrofit only. If you are an OEM, please refer to the OEM

7

Components Required

2

4

1

LED light

2

LED driver

3

Wire cover

4

M3.5x1.3x13 (#6-32 x 1/2 inch) screws

5

Twist lock splice wire connectors

Fluorescent Component Location

Installation Guide.

• Refer to manufacturing manual for refrigeration case to
identify lighting control circuits. Ensure that power is switched
off at the service panel for the lighting circuit. If a lighting
power switch is not provided in the refrigeration case, power
removal can be performed at the main breaker panel.

• Locate existing lighting components including ballasts,
lampholders, lamps, and lampguards in the refrigeration
case for removal. Please refer to refrigeration manual for any
questions dealing with component locations.

• Remove lamps, lampholder and lamp guards. Cut the wiring,
making the cut as close to the lampholder as possible. Do not
remove wiring from case as it will be utilized to attach the LED
light. Dispose of components per federal and local regulations.

• Locate ballast within system. The most common location is in
the mullion or the electrical raceway found in the bottom of
the refrigerated case.

• Disconnect ballast input and output connectors. Cut the
ballast connector wires nearest to the connector and remove
connector. Unscrew the mounting screws that attach ballast
and remove ballast. Dispose of ballasts according to federal
and local regulations. LED driver installation will begin at Step
7 and Step 8.

• To install the LED light, first identify the wiring for connection
to the LED driver. After removing the connector from ballast,
leave the existing ballast input and output wires for

reconnection in a later step.

2

Lamp with lamp guards

A

(behind mullion)

Lamp holders

B

Ballast

C

1. Mullion

2. Raceway

3. Overhead door frame

1

3

5

2

of mullion

Total width

10 mm (3/8")

For 750 mm (30-inch)

LED Lights:

687 mm (27 1/32")

Center

punch

at intersection

and drill a

2.8 mm (7/64")
hole

mullion

Half total

width of

LED Driver wires ­top

For 900 mm (36-inch)

LED Lights:

836 mm (32 29/32")

Prepare for Installation of
Center LED Lights

• Measure the total width of the mullion, and mark a vertical
line half the total width near the top and bottom of the mullion.

•

Prepare for the upper end of the Center LED Light . Mark a
horizontal line a minimum 54 mm (2 1/8-inches) from the top
of the mullion, and another horizontal line 10 mm (3/8-inches)
below this line.

• Prepare for the lower end of the Center LED Light . For
750 mm (30-inch) LED Lights, mark a horizontal line 687 mm
(27 1/32-inches) beneath the first line drawn for the top
Mounting Tab. For
horizontal line 836 mm (32 29/32-inches)
line drawn for the top Mounting Tab.

• Point the center punch directly at the intersection of the
horizontal lines and the vertical line (top and bottom)
establish a dimple.

• Use power drill and 2.8 mm (7/64-inches) drill bit to drill
holes at the
horizontal lines.

900 mm (36-inch) LED Lights, mark a

beneath the first

and

intersection of the vertical center line and the

3

WARNING / AVERTISSMENT

Risk of electrical shock. Only those open holes indicated in the photographs and/or drawings may be made or altered as a result of kit installation. Do not leave
any other open holes in an enclosure of wiring or electric components / Risque de choc électrique. Seuls les trous ouverts indiqués dans les photos et / ou les
dessins peuvent être faites ou modifiés à la suite du montage du kit. Ne pas laisser autres trous ouverts dans l'enceinte du câblage électrique ou composants.

Install Center LED Lights

LED Driver

• Place the Center LED Light against the face of the

mullion

near the two holes drilled at the top.

• Insert a M3.5 x 1.3 x 13 (#6-32 x ½-inch) sheet metal screw
into the top slot of the Mounting Tab on the Center LED Light
and into the first hole that was drilled in the center mullion.

• Use a screwdriver to start threading the screw into the
drilled hole.

• Refer to the manufacturing manual for door frame to ensure
there are no components contained inside the mullion that
could be drilled through. Use a M3.5 x 1.3 x 13 (#6 - 3/4-inch)
self-drilling screw to attach the Center LED Light into one
or two of the additional drill through holes located near the
center of the LED Light.

• Repeat for the second screw, and for the lower end of the
Center LED Light.

• Refer to wiring diagram on page 5. Connect the red and black
output wires from the LED Light to the red and black wires on the
LED Driver using the twist lock splice wire connectors provided.

Mounting Tab

Center LED Light

Power Leads

Leads

3

R

5 C
N
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6-Door Case

LED Driver
Configuration Options

The diagrams below represent wiring
configurations for each LED Driver.

5-Door Case 4-Door Case

LED

DRIVER

LED

DRIVER

LED

DRIVER

LED

DRIVER

3-Door Case

LED

DRIVER

2-Door Case

LED

DRIVER

Parts Needed Per Case

Center LED Lights 543 21
End LED Light Sets 111 11
LED Drivers 211 11
Wire Covers 76543

6-Door 5-Door 4-Door 3-Door 2-Door

4

TERMINAL BLOCK

LED DRIVER

WHITE (NEUTRAL)

BLACK (LINE)

SWITCH

B

RBR

B

W

B

R

G

RIGHT END LED LIGHT

LEFT END LED LIGHT

A

C

B

D

Occupancy Sensor

Gray Purple

ARNING / AVERTISSMENT

TERMINAL BLOCK

LED DRIVER

WHITE (NEUTRAL)

BLACK (LINE)

SWITCH

BR B R

BW

BR

G

END (R or L) LED LIGHT

CENTER LED LIGHT

A

C

B

D

Occupancy Sensor

Gray Purple

TERMINAL BLOCK

LED DRIVER

WHITE (NEUTRAL)

BLACK (LINE)

SWITCH

BR

BW

BR

G

CENTER LED LIGHT

A

C

B

BR

LEFT END LED LIGHT

BR

RIGHT END LED LIGHT

D

Occupancy Sensor

Gray Purple

TERMINAL BLOCK

LED DRIVER

WHITE (NEUTRAL)

BLACK (LINE)

SWITCH

BR

BW

B

R

G

CENTER LED LIGHT

A

C

B

D

Occupancy Sensor

Gray Purple

TERMINAL BLOCK

LED DRIVER

WHITE (NEUTRAL)

B

LACK (LINE)

SWITCH

BR BR

BW

BR

G

CENTER LED LIGHT

CENTER LED LIGHT

A

C

B

D

O

ccupancy Sensor

G

ray Purple

W

Risk of electrical shock. Ensure that all connection points are sealed for damp location using the appropriate method per the NEC or local
electrical code.

Risque de choc électrique. S’assurer que les points de raccordements sont scellés pour emplacement humide en employant une

méthode permise par le NEC ou par le code électrique local.

4

Connection Configurations

For information on A, B, C, D, see Steps 4, 5 and 6.

One End Set (R & L) LED Lights

Note: LED Lights are polarity insensitive

Two Center LED Lights

Note: LED Lights are polarity insensitive

C C C

B

TERMINAL BLOCK

(AC Source)

B

TERMINAL BLOCK

(AC Source)

One Center LED Light

Note: LED Lights are polarity insensitive

B

TERMINAL BLOCK

(AC Source)

One End Set (Right and Left) &

One Center LED Light

Note: LED Lights are polarity insensitive

C

B

TERMINAL BLOCK

(AC Source)

One End LED Light (Right or Left) &

One Center LED Light

Note: LED Lights are polarity insensitive

C

B

TERMINAL BLOCK

(AC Source)

5

Wire Cavities

39-01-4030 (AC)

Cavity 1 - Line 1 (Black)
Cavity 2 - Earth Ground (Green)
Cavity 3 - Neutral or Line 2 (White)

39-01-4046 (DC)

Cavity 1 - Output DC (+) (red)
Cavity 2 - Output DC (-) (black)
Cavity 3 - Dimming (Purple)
Cavity 4 - Dimming (Gray)

5

Connect LED Driver - Output

• Make output (DC) connections using one of the two options below:

6

OPTION 1 – USING 4-WAY CONNECTOR

Connect the LED Driver output leads to the LED Light leads

sing the appropriate mating connector (Molex P/N 39-01-

u

4046). Terminals
tooling and process per Molex specifications. Ensure that the
connector cavities are correctly populated per the

ire cavity table on page 5.

w

installed should be crimped using approved

A

OPTION 2 – USING TWIST-ON WIRE CONNECTORS

Remove the 4-way connector from the LED Driver by

utting the wires near the connector and strip the output

c
leads. Using the appropriate wiring diagram on page 5,
connect the LED Driver output leads to the LED Light leads
using wire connectors or other connection method approved

or low temperature usage and stranded cable. (A)

f

For non-dimming applications, cap the unused wires with
4mm (5/32") twist on wire connectors.

Connect LED Driver - Input

• Make input (AC) connections using one of the two options below:

• The LED Driver is required to be reliably bonded to the protective ground conductor.

OPTION 1 – USING 3-WAY CONNECTOR

Attach the supplied green/yellow ground wire from the
LED Driver to a grounded metal portion of the door frame.
Connect the original Line and neutral wires (or Line 1 and
Line 2 wires for 240 nominal VAC) to the 3-way connector
for the LED Driver input wires using the appropriate
matingconnector (Molex P/N 39-01-4030). Ensure that
the connector cavities are correctly populated per the
wire cavity table on page 5.

C

OPTION 2 – USING TWIST-ON WIRE CONNECTOR

Attach the supplied green/yellow ground wire from the
LED Driver to a grounded metal portion of the door frame.
Remove the 3-way connector from the LED Driver by cutting
the wires near the connector and strip the input wires. Using
the appropriate wiring diagram on page 5, connect the
original Line and neutral wires (or Line 1 and Line 2 wires for
240 nominal VAC) to the LED Driver leads using twist lock wire
connectors
temperature usage and stranded cable. Ensure that the
connector
table on page 5.

A

B

or other connection method approved for low

cavities are correctly populated per wire cavity

C

7

Connect Dimming Contacts – Output (Optional)

• To enable dimming operation, connect leads from occupancy sensor or control system (normally open contact) to the purple
and gray leads of the power supply.

• Make output (contact closure) connections using one of the two options below:

OPTION 1 – USING 4-WAY CONNECTOR

Connect the LED Driver dimming output leads to the
occupancy sensor or control system using the appropriate
mating connector (Molex P/N 39-01-4046). Terminals installed
should be crimped using approved tooling and process per
Molex specifications. Ensure that the connector cavities are

D

correctly populated per the wire cavity table on page 5.

• The LED Driver is capable of step dimming from 100% power to 20% power when used with a normally
occupancy sensor system.

• When using the LED drivers for non-dimming applications, the dip switch setting must be set to #1 ON to

disable the dimming feature and achieve 100% illumination.

(D)

OPTION 2 – USING TWIST-ON WIRE CONNECTORS

Remove the 4-way connector from the LED Driver by
cutting the wires near the connector and strip the output
leads. Using the appropriate wiring diagram on page 5,
connect the LED Driver dimming output leads to the
occupancy sensor or control system using wire connectors
or other connection method approved for low temperature
usage and stranded cable. (D)

D

open contact closure

6

CAUTION / ATTENTION

Risk of electrical shock. Plastic cover is needed to protect electrical wires from tampering and accidental contact. / Risque de choc électrique.
Le couvercle en plastique est requis pour assurer une protection adéquate contre l'accès aux fils et les contacts accidentels.

8

Attach Covers to End Cap

• Tuck wires underneath Wire Cover before installing it onto
the End Cap.

• Attach Wire Cover to LED Light End Cap by inserting a
M2.9x10 pan head tapping screw (provided) through the
holes in Covers and Mounting Tabs using an installation
torque 0.32 N-m (3 lbf-in)

NOTE:

Tighten slowly until fully seated, do not over tighten

or strip the threads.

WARNING / AVERTISSMENT

Risk of electrical shock. Disconnect power to LED Lights before any cleaning operation.
Risque de choc électrique. Débranchez l'alimentation des éclairages à LED avant toute opération de nettoyage.

Wire

over

C

End Cap

M2.9x10 pan
head tapping
screw

9

LED Refigerated Display Lights – Cleaning Instructions

• The outer lens and the plastic housing should be cleaned
periodically with a mild liquid dish detergent.

• Do not use chemical cleaners to clean the lens.

• Keep the outside clean. Wipe with a clean cloth lightly
dampened with mild liquid dish detergent. Dry with a clean,
soft cloth.

This product is intended solely for the use of commercial refrigerated, display or case lighting and is not intended for use in
any other application.

GE Lighting Solutions • 1-888-MY-GE-LED • www.gelighting.com

1-8 88-6 9-4 3-533

GE Lighting Solutions, LLC is a subsidiary of the General Electric Company. Immersion is a trademark of GE Lighting Solutions, LLC. The GE brand and logo are trademarks of the General Electric Company.
© 2013 GE Lighting Solutions, LLC. Information provided is subject to change without notice. All values are design or typical values when measured under laboratory conditions.

• Do not wipe the lens with a soiled dish cloth or wet towel.
These may leave a residue that can damage the finish.

• Do not use scouring pads, powdered cleaners, bleach or
cleaners containing bleach because these products can
scratch and damage the finish.

7

11776-R110813