KELSEY - CSS Cable Suspended Rotational and Static CSS - Cable Suspended 3-O or 4-0 MUD RING BRACKET BAR 1/4-20 STUD 8-32 BRACKET BAR SCREWS STRAIN RELIEF POWER CORD MOUNTING GRIPPER AIRCRAFT CABLE CABLE GRIPPER ROTATIONAL KNUCKLE / END CAP ASSEMBLY (KEL225-CSS-R SHOWN) ROTATIONAL CABLE SUSPENDED COMPONENTS 3-O or 4-0 MUD RING BRACKET BAR CABLE GRIPPER/ MOUNTING STUD 8-32 BRACKET BAR SCREWS STRAIN RELIEF POWER CORD MOUNTING COUPLER AIRCRAFT CABLE 1/4 MACHINED CLEAN END CAP (KEL125-CSS-DR SHOWN) DOWNLIGHT CABLE SUSPENDED COMPONENTS 1/4-20 STUD BY OTHERS 1/4-20 SIDE EXIT GRIPPER R - ROTATIONAL END CAP STND - 5 NC - NO CR-CONTINUOUS RUN STARTER/ END FIXTURE HOUSING ALIGNERS WITH SET SCREWS L BRACKET CONTINUOUS RUN BRACKET WITH THREADED STUDS SUPPLIED NUTS AND WASHERS MIDDLE FIXTURE 1. See cable spacing guide for correct J-box spacing. 2. Insert cable into gripper ends and adjust to desired length. 3. Insert power cable through canopy and secure with provided strain relief. 4. Complete wire makeup. 5. Install canopy with cable gripper parts. 6. Cut cables to desired length - be careful not to fray cable ends. Only for CSS-R 7. Loosen set screw on knuckles 8. Rotate fixture as desired. 9. Tighten to stop rotation. Continuous Run Info 1. Install starter fixture (aircraft cable & power feed). 2. Adjust to desired / specified height. 3. Cut and cap aircraft cable inside J-box. 4. Secure canopies. 5. Install next fixture - cable, power feed if necessary and canopy setup. 6. Slide open end of fixture (side with no cable setup) over starter fixture s continuous run bracket studs and cable mounting plate. 7. Secure with supplied washers and nuts (Note: the internal L bracket should be set back approximately 1/16 from the edge of the fixture - they can be adjusted if necessary). 8. Tighten set screws on housing aligner. 9. KEL125 has a power drop of each fixture. The connection with alignment pins and pinch brackets. 10. If integral ballast, thru wire with appropriate gauge wire 11. Continue installation with all other fixtures. HOUSING ALIGNERS used only on 225 & 325 33
KELSEY - CSS Cable Suspension System Direct, Indirect, and Rotational CSS - Cable Spacing CENTER TO CENTER DIRECT LIGHT CABLE MOUNTING DISTANCES OR CABLE CENTERS BY FIXTURE DIRECT See continuous run matrix pages for fixture length and cable spacing CENTER TO CENTER INDIRECT LIGHT CABLE MOUNTING DISTANCES OR CABLE CENTERS BY FIXTURE INDIRECT MOUNTING DISTANCES CENTER TO CENTER ROTATIONAL V-1212 34
KELSEY - RAS Arm Length and Spacing Standard Cover Plate AND 3-O MUD RING (provided by others) RAS Arm Spacing Guide MOUNTING PLATE OPTIONAL MACHINED ALUMINUM TOOL-LESS COVER PLATE ARM LENGTH MEASUREMENT: MOUNTING SURFACE TO CENTER OF FIXTURE 8-32 FLAT HEAD MACHINE SCREWS ARM LENGTH 5/8 DIA. ALUMINUM ARM 1-1/4 DIA. x 1-1/8 LONG MACHINED END KNUCKLE (center knuckles have the same dimensions) (KEL225-RAS shown) ARM AND KNUCKLE DIMENSIONS 1-1/4 DIAMETER x 1-1/8 LONG KNUCKLE 5/8 DIAMETER ARM See continuous run matrix pages for fixture length and cable spacing 1/4 THICK PRECISION MACHINED END CAPS 35
KELSEY - RAS No Mounting Plate and Trim Ring RAS-NMP/ TR1 Trim Ring Options NMP - No Trim Option 1. Align fixture arms and tighten set screws (insure rotation is possible, arms can be adjusted to where the fixture cannot rotate). APPROVED ELECTRICAL ENCLOSURE TR1-1 Trim Ring Option STANDARD 1/4 IPS 3 INSERT WILL HAVE 2 1/2 OF EXPOSED THREADS. CONTACT FACTORY FOR ALTERNATIVE CONFIGURATIONS TRIM RING 5/64 ALLEN WRENCH NO TRIM RING STANDARD 1/4 IPS 3 INSERT WILL HAVE 2 1/2 OF EXPOSED THREADS. CONTACT FACTORY FOR ALTERNATIVE CONFIGURATIONS 2. Drill 33/64 or 17/32 holes in mounting surface. Reference Fixture Spacing worksheet for spacing information. 3. Approved electrical enclosure must be installed on the back side of the mounting surface. 4. If using trim ring, slide one over each threaded nipple. 5. Install fixture - insert adjustable threaded ends through drilled holes. 6. Slide on flat washer and star washer. 7. Securely tighten with nuts on each arm 8. Run wires via supplied coupler and 3/8 flexible conduit fittings to J-Box or ballast housing and complete wire make-up per supplied wiring diagram. 9. Use 5/64 Allen wrench to loosen fixture at arm knuckles. APPROVED ELECTRICAL ENCLOSURE 10. Adjust fixture as desired and tighten set screws to secure in place. Set screw may be left loose for adjustment if desired. 5/64 ALLEN WRENCH WITH TRIM RING 36
Standard Cover Plate KELSEY - RAS 3-0 Mounting Plate RAS 3-0 Mounting Plate 1. Install J-box with Mud Ring (provided by contractor). -Use fixture mounting center chart (on RAS arm spacing page). It is critical that these dimensions are precisely followed. 1. 2. Slide cover plates over arms, slide threads through mounting plate, star washer and flat washer, securely tighten with nut - make sure mounting holes align with mud ring holes. 2. 3. Complete wire make-up per code to J-Box or ballast housing and complete wire make-up per supplied wiring diagram. 4. Securely mount fixture to wall with provided 8-32 flat undercut head screws (Hex head screws provided for short arm applications, Allen wrench not provided). 5. Slide cover plate over mounting plate (magnets with pull cover plate tight against wall). 3. 6. Use Allen wrench to loosen fixture at arm knuckles. 7. Adjust fixture as desired and tighten set screws to secure in place. Set screw may be left loose for adjustment if desired. 4. 5/64 ALLEN WRENCH 37
KELSEY - RAS - TB TB - Cable Tie Back System RAS - TB - Cable Tie Back Option 1. During fixture installation, attach arm ring to desired position. Should be set to at the middle of arm to be most effective. 2. Attach 1/4-20 threaded set screw to secure arm ring to arm and thread on cable gripper to set screw. 3. Cut off die-cast end stop on aircraft cable, being careful not to fray ends. Feed aircraft cable into gripper, attach to arm ring. 4. Attach cable gripper to 1/4-10 stud at wall to same distance that ring in set at, to create a 45 degree angle. 5. Feed aircraft cable through the safety nut to desired length (cut extra cable if necessary) cable length ring location arm length 38
KELSEY - RAS Continuous Run IB Installation Connection & Wiring/ Integral Ballast A INTEGRAL Fixture 1 Fixture 2 Continue wiring through the knuckle Wiring power to ballast and continue to next fixture 1. Install J-box with Mud Ring (provided by contractor). 2. Slide cover plates over arms, slide threads through mounting plate, star washer and flat washer, securely tighten with nut - make sure mounting holes align with mud ring holes. 3. Complete wire make-up per code to J-Box or ballast housing and complete wire make-up per supplied wiring diagram. B REMOTE Fixture 1 Fixture 2 4. Securely mount fixture to wall with provided 8-32 flat undercut head screws (Hex head screws provided for short arm applications, Allen wrench not provided). 5. Slide cover plate over mounting plate (magnets with pull cover plate tight against wall). 6. For integral ballast fixtures, through wire out of 1st fixture, through the knuckle into the second fixture and connect the power to the ballast. (A) C 7. For remote ballast fixtures, feed wiring from ballast box into J-box. Bring wiring from fixture, through the knuckle and arm to the J-box to complete wire make up. (B) 8. Connect 2nd fixture into knuckle, tighten set screw to lock into place.(c) Bottom View Set Screws 5/64 Allen Wrench 9. To rotate and aim fixture into desired position, use allen wrench to loosen fixture at arm knuckles (C) Lock fixture into place tighten set-screw. Set screw may be left loose for adjustment if desired. 39
Fixture mounting instructions KELSEY 125 - SM Surface Mount Instructions LED / Fluorescent SM - Surface Mount 1. Remove lens and internal reflector. POWER FEED HOLE CENTERED IN BACK OF HOUSING FOR 2-4 AND 6 OFF CENTER FOR 6 AND 8 FIXTURES 1/2 FROM BRACKET 1/2 FROM BRACKET MOUNTING SUPPORT HOLES SIZE AND LOCATION BY CONTRACTOR DRILL INTO STRUCTURAL SUPPORT 2. Bring 3/8 flex conduit whip out of wall and attach to provided conduit fitting. 3. Feed wires (9 of wire provided as a standard) back to remote ballast box and make up wires per wiring diagram provided. 4. Drill appropriate holes in desired location, ensure that they are not within the end cap bracket openings. 3/8 FLEXIBLE CONDUIT FITTING 5. Securely mount fixture to surface with appropriate fasteners (by others) Mounting hole to be drilled by contractor, outside of bracket area, use low profile head fastener (by others) 1/2 from bracket. End cap bracket with set scew Socket Clip End cap bracket opening 6. For continuous runs, install next fixture by repeating steps 1-4. Connect fixtures using provided flat plate with set of screws. Secure second fixture via appropriate fasteners so that the fixtures will only have a hairline seam when joined. Tighten set screw on joining flat plate. Repeat as necessary for sequential fixtures. 7. Re-install internal reflector, ensure that no wires get pinched between the liner and structure under the liner (captive nut of end cap bracket, mounting screw, etc.) 8. Re-install lens. 40
KELSEY 225/325 SM Surface Mount Instructions LED / Fluorescent SM - Surface Mount Fixture mounting instructions POWER FEED HOLE - 1/2, 5/8 or 7/8 DIAMETER HOLE SIZE AND LOCATION BY CONTRACTOR 1. Install J-Box with mud ring, single gang mud ring horizontally mounted, or other suitable UL approved J-Box.. 2. Remove lens or louver (if applicable) and internal reflector. MOUNTING SUPPORT HOLES SIZE AND LOCATION BY CONTRACTOR DRILL INTO STRUCTURAL SUPPORT 3. Determine fixture s location on wall and note/mark the center of the J-Box on the fixture. or WHIP 4. Drill appropriate size hole for wire feed through fixture - NOTE: Do NOT drill into power supply or reflector mounting area if wall mount or up-light - Relocate power supply if necessary. Insert bushing (by others). KELSEY WALL MOUNT LIGHT STRAIGHT OUT 5. Drill mounting support holes near ends of fixture - support method to be determined (TBD) by contractor. or WHIP MUD RING OR HORIZONTALLY MOUNTED SINGLE GANG MUD RING OR WHIP OUT OF WALL or WHIP 6. Complete wire make-up. 7. Securely mount fixture to surface. 8. Re-install reflector. MOUNTING HARDWARE BY CONTRACTOR 9. Install lamp KELSEY WALL MOUNT UPLIGHT DO NOT MOUNT THROUGH LENS ENGAGEMENT AREA KELSEY WALL MOUNT DOWNLIGHT 10. Replace lens or louver. 41