EATON IF 1948 Champ Pro PLLA M2 Series Linear Emergency LED Luminaire Fittings Installation Guide

CROUSE-HINDS
SERIES

Champ® Pro PLLA M2 Series Linear Emergency LED
Luminaire Fittings
Installation & Maintenance Information

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

APPLICATION

CHAMP Pro Linear Emergency LED luminaire are suitable for use in the following locations as defined by the National Electrical Code (NEC®):
The assembled luminaire shall be installed in accordance with the National Electric Code NFPA70, and American Bureau of Shipping.

NEC

• Wet location, IP66/67, Type 4X

UL Standards:

• UL1598 Luminaires, UL1598A Marine
• UL8750
• UL924

CSA Standard:

• CSA C22.2 No. 250
• CSA C22.2 No. No.141

These luminaire housings shall be used with UL listed Crouse-Hinds ordinary locations luminaire fittings namely LED Light Engine Cat Nos. PLLA2 or PLLA4 series ending with M2 and Mounting means Cat Nos. M2-FLUSH- MT-KIT, M2 -CEILING-SWIVEL-KIT, M2-CEILING-WALL-KIT, M2-PM-KIT-1.25, M2-PM-KIT-1.5, M2 -PM-KIT-2.0, (refer to label provided inside the driver housing for permissible fitting details).
Refer to the luminaire fitting nameplate for specific classification information, maximum ambient temperature suitability, and corresponding operating temperature (T-code).
The assembled linear LED luminaire is designed for use indoors and outdoors in marine and wet locations, where moisture, dirt, corrosion, vibration and rough usage may be present.

INPUT VOLTAGE:

• UNV1: 120-277 VAC 50/60 Hz

IMPORTANT SAFEGUARDS

When using electrical equipment, basic safety precautions should always be following including the following:

IMPORTANT SAFEGUARDS – READ AND FOLLOW ALL SAFETY INSTRUCTIONS

1. Read carefully before installing and wiring luminaire and retain for future reference.
2. The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition.
3. Use only replacement parts from Eaton’s Crouse Hinds division.
4. To avoid the risk of fire, explosion or electric shock, this product should be installed, inspected and maintained by a qualified electrician only, in accordance with all applicable electrical codes.
5. Do not mount near gas or electric heaters.
6. Do not use this equipment for other than intended use.
7. Replace entire battery unit and LED driver when necessary. Contact the manufacturer for information on service.
8. Do not attempt to service battery.
9. See product label for minimum supply wire temperature rating.
10. Battery requires 24hrs to fully charge. Allow 24 hours charging time before depending on the battery to operate at full capacity.
11. The emergency battery requires a minimum charge time of one (1) hour before testing the circuit, 24 hours is required for a full charge.
12. Equipment should be mounted in locations and at heights where it will not readily be subjected to tampering by unauthorized personnel. Max. mounting height: 25.2 feet)
13. The emergency luminaire is intended to be installed with CG-256 (issued by the American Bureau of Shipping and Coast Guard.
14. 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 the hazards involved.

WARNING
To avoid electric shock:
Be certain electrical power is OFF before and during installation and maintenance.
Luminaire must be supplied by a wiring system with an equipment grounding conductor in accordance to the NEC and CEC for the specific location involved.
To avoid burning hands:
Make sure lens and housing are cool when performing maintenance.

STORAGE INSTRUCTIONS

1. EM luminaire must be stored in an ambient temperature range of 0°C to 40°C.
2. Battery should be charged and discharged within 6 months. At a minimum, the battery should be recharged within this time

WARNING
To avoid explosion:
Make sure the supply voltage is the same as the luminaire voltage.
Do not operate in ambient temperatures above those indicated on the luminaire nameplate.
Use proper supply wiring as specified on the luminaire nameplate.
All gasket seals must be clean and undamaged.
Before opening, electrical power to the luminaire must be turned off.
Keep tightly closed when in operation.
Clean only with damp cloth.

INSTALLATION

Max. mounting height of 25.2 ft (7.68m)

A. M2-FLUSH-MT-KIT

1. Make sure the power is disconnected to the conduit system before installing the luminaire.

2. Install flush mount brackets to rear of luminaire driver housing using the provided two (2) 1/4” hex bolts and split ring lock washers for each bracket. Bracket orientation as shown in Figure 1. Torque to 64 in.-lbs (7.2 N-m)

3. Identify mounting location suitable for supporting luminaire, mark and drill holes for flush brackets per dimensions shown in Figure 1.

4. Luminaire is now ready for mounting. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the luminaire. This is recommended to avoid any personal injury or damage to the luminaire.
   WARNING
   To avoid injury to personnel, do not let the luminaire hang or flex on one bracket at a time. Failing to comply will result in breakage of bracket and possible injury or death.

5. Install and tighten four (4) 1/4” diameter fasteners (customer supplied) in bracket mounting holes. It is recommended that stainless steel hardware be used in locations with corrosion concerns.

Length| 2 Foot (in)| 2 Foot (mm)| 4 Foot (in)| 4 Foot (mm)
---|---|---|---|---
A| 24.0| 610| 39.0| 991
B| 24.25| 616| 24.25| 616
C| 2.50| 63.5| 2.50| 63.5

B. M2-CEILING-WALL-KT

1. Make sure the power is disconnected to the conduit system before installing the luminaire.

2. Mark and drill holes for fastening end brackets. Use two (2) 1/4” diameter fasteners (customer supplied) at center to center measurements (see Figure 2). It is recommended that stainless steel hardware be used in locations with corrosion concerns.

3. Luminaire is now ready for mounting. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the luminaire. This is recommended to avoid any personal injury or damage to the luminaire.

4. For end mount wall/ceiling mounting brackets, it is recommended to mount one bracket first and then, while supporting the luminaire, insert it into the mounted bracket, then attach the other bracket.
   WARNING
   To avoid injury to personnel, do not let the luminaire hang or flex on one bracket at a time. Failing to comply will result in breakage of bracket and possible injury or death.

5. Aim the luminaire to achieve desired light output and tighten the 1/4” set screws on brackets. Torque to 64 in.-lbs. (7.2 N-m).

6. Use set screw to limit rotation of the luminaire.

Length| 2 Foot (in)| 2 Foot (mm)| 4 Foot (in)| 4 Foot (mm)
---|---|---|---|---
A| 28.5| 724| 28.5| 724
B| 24.0| 610| 39.0| 991

C. M2-CEILING-SWIVEL-KIT

1. Make sure the power is disconnected to the conduit system before installing the luminaire.

2. Identify mounting location suitable for supporting the luminaire, mark and drill holes for fastening swivel brackets per center-to-center dimension ‘A’ in table below (see Figure 3).

3. Mount swivel bracket assemblies to luminaire driver housing as shown in Figure 3. Use two (2) of the provided 1/4” hex bolts and split ring lock washers for each bracket. Torque to 64 in-lb (7.2 N-m).

4. Luminaire is now ready for mounting. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the luminaire. This is recommended to avoid any personal injury or damage to the luminaire.

5. Install and tighten 1/4” diameter fasteners (customer supplied) in each of the bracket mounting holes. It is recommended that stainless steel hardware be used in locations with corrosion concerns.
   WARNING
   To avoid injury to personnel, do not let the luminaire hang or flex on one bracket at a time. Failing to comply will result in breakage of bracket and possible injury or death.

6. Adjust the position of the luminaire to the desired angle and tighten the two (2) 5/16” pivot bolts snugly to the bracket and then tighten hex nuts. Torque to 120 in.-lbs. (13.6 N-m).

Length| 2 Foot (in)| 2 Foot (mm)| 4 Foot (in)| 4 Foot (mm)
---|---|---|---|---
A| 26.4| 670| 26.4| 670
B| 24.0| 610| 39.0| 991

**D. M2-PM-KIT-***

1. Make sure the power is disconnected to the conduit system before installing the luminaire.

2. Verify that the clamp internal diameter is consistent with the diameter of the pole prior to installation. Clamps are available in 1.65 (42mm), 2.00 (51mm) and 2.36 (60mm) sizes (see Figure 5).

3. Pole mount brackets are spaced 20.75” on the bracket centerlines as shown in Figure 4.

4. Tighten two (2) of the provided 1/4” hex bolts and split ring lock washers on each bracket sub-assembly. Torque to 64 in-lbs (7.2 N-m).

5. Remove the two (2) 5/16” screws, lock washers and nuts on each clamp and remove the upper clamp halves.

6. Luminaire is now ready for mounting. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the luminaire. This is  recommended to avoid any personal injury or damage to the luminaire.

7. Lift luminaire into position such that the pole fits into the lower clamp halves.
   WARNING
   To avoid injury to personnel, do not let the luminaire hang or flex on one bracket at a time. Failing to comply will result in breakage of bracket and possible injury or death.

8. Install the two (2) upper clamp halves and the 5/16” screws, lock washers and nuts on each clamp.

9. Tighten the nuts on the 5/16” screws evenly using a back and forth sequence. Torque to 120 in.-lbs. (13.6 N-m).

Length| 2 Foot (in)| 2 Foot (mm)| 4 Foot (in)| 4 Foot (mm)
---|---|---|---|---
A| 24.0| 610| 39.0| 991
B| See table below for pipe clamp diameters

E. PENDANT MOUNT INSTRUCTIONS

1. Make sure the power is disconnected from the conduit system before installing the luminaire
2. For Pendant Mount the conduit should be located in line with the 3/4” NPT entry on the rear of the luminaire driver housing (see Figure 6).
3. Luminaire is ready for mounting. It is strongly suggested to use two (2) qualified tradespeople to proceed with the final mounting of the luminaire. This is recommended to avoid any personal injury or damage to the luminaire.
4. Verify sufficient quantity of Eaton’s STL thread lubricant is on conduit entries and that all unused conduit entries on the end caps are closed with lubricated plugs (see Figure 13).
5. Engage threaded conduit in rear driver housing NPT entry and fully tighten in to desired position for operations (engage at least 3-1/2 threads).
6. Tighten set screws on driver housing as shown in Figure 8. Torque set screws to 20 in-lb (2.3 N-m).
7. Luminaire now ready to make electrical connections. See section titled Wiring The LED Luminaire for detailed instructions.

Length| 2 Foot (in)| 2 Foot (mm)| 4 Foot (in)| 4 Foot (mm)
---|---|---|---|---
A| 24.0| 610| 39.0| 991

SECONDARY SUPPORT
If using secondary support, attach one end of the support cable to one of the four (4) attachment points provided on the luminaire driver housing and secure the other end to a fixed support. Use a minimum of two (2) support cables per luminaire, securing a single cable at two (2) locations on the exterior of the luminaire driver housing.
Arrange the secondary support cables to limit the suspended vertical distance to no more than 18 inches from the primary mounted position. Cables must be installed in this manner to limit the potential vertical drop to 18 inches maximum.

PUSH-TO-TEST SWITCH
A remote push-to-test switch (not supplied) suitable for the classified area must be wired in the supply circuit to periodically test the emergency operation feature (see wiring diagrams). The switch used must be suitable for the area classifications.
Important instructions for remote mounting of push to test switch (customer supplied):
a. Switch shall be installed using acceptable wiring methods for the areas involved in accordance with the NEC.
b. Switch shall be connected to the emergency luminaire circuit such that when depressed it provides a transfer function and disconnects and isolates the normal input from the emergency input.
c. Switch shall be identified as to its function (i.e. – marked “Emergency Luminaire Test Switch”).
d. Switch shall have electrical ratings suitable for the emergency luminaires.
e. Switch shall be manually operated type.
f. Switch shall be of Momentary-contact type.
g. Switch must be visible and accessible without the use of tools.
STATUS INDICATOR LIGHT
The status indicator light located on LED board (Red LED) will be “ON“ when the battery is charging. If the status LED is flashing, replace emergency driver unit.. If required customer can remote mount their own status indicator light with suitable electrical ratings. Contact Eaton’s Crouse-Hinds for additional support.
For remote mounting of Status Indicator light refer to figure below “Remote mounting Test switch & Status indicator”.

EMERGENCY DRIVER UNIT INFORMATION
Champ Pro Emergency Linear LED luminaires are supplied with an emergency driver unit. Disconnect the battery converter connector (Red-Red wires) prior to performing maintenance (Refer to Figures 14A, 14B or 14C). This will disconnect the charged battery from the LEDs. The emergency driver unit must be checked periodically to ensure that it is working properly.

IMPORTANT INSTRUCTIONS (for customer supplied wall switch)

1. Installations in which a remote wall switch is to be used, connect an unswitched supply line to the Black wire (L) and a switched supply line to the White/Red wire (L1) of the Emergency Backup Module. Refer to wall switch connection details on Wiring Diagrams in Figures 14A, 14B and 14C.
2. When the switched supply line (L1) is de-energized using the wall switch, the luminaire will turn off light output while the battery circuit remains active and charging.
3. Upon the loss of line power to the Emergency BackupModule, the luminaire will immediately operate in Emergency Operations mode (automatic switching) with a reduced light output .
4. If the unswitched supply line is connected to Black wire (L) only, battery will charge, and luminaire will be in OFF condition (i.e AC driver is not in operating condition). This is the Emergency Operations Only mode and the luminaire shall only be illuminated on the loss of the line power.
5. The wall switch used shall be suitable for 120 – 277VAC and15A operations.

WIRING THE LED LUMINAIRE

1. Assembly sequence is common to both the Pro PLLA2 and Pro PLLA4 LED luminaire products. The Pro PLLA2 luminaire is used in the supporting illustrations.

2. To gain access to the luminaire input wiring connections loosen the eight (8) #10-32 x .75” stainless steel cover screws (see Figure 9) until screws are free from driver housing. Screws are a captive type and should not be fully removed from the light engine fitting assembly.
   

3. Pull the retention clips on the light engine assembly to free it from the driver housing and pivot the light engine fitting on the driver housing service hooks (see Figure 10). This shall expose the internal volume of the driver housing and the input wiring terminal carriers.

4. Connections to the LED light engine and LED driver are pre-wired and do not require any further processing. Route the Line, Neutral and Ground input wires to the wire terminal carrier (see Figure 11) and make connections per system wiring diagrams (see Figures 14A, 14B and 14C) using methods that comply with all applicable codes. Terminate the equipment grounding connector (green) first, the common (white) next, and finally, the line voltage (black). Ensure all electrical connections have been completed and terminal block lever locks are fully seated and secure.
   Note- standard entries in driver housing and 3/4” NPT thread.

5. Connect module battery connections (white wires) as the battery is shipped disconnected to prevent discharging.

6. Connect Emergency Backup Module converter connection (Red wires) as the last electrical connection. This connection enables electrical function in the backup module and failure to make this connection will result in nonfunction of the luminaire.

7. If using the dimming function of the LED driver, use only wires rated to 600V minimum. Dimming circuit operates on 0-10 VDC; dimmer shall be suitably certified for the intended installation environment (e.g. Hazardous, Ordinary Locations, etc…).

8. Re-install the light engine fitting and tighten all eight (8) cover mounting screws 23 in.-lbs. (2.6 N-m) using the bolting sequence directed in Figure

9. Verify that no luminaire wiring is pinched or trapped between light engine and driver housing. Start all screws prior to tightening.

10. Replace any damaged or missing cover screws. Consult factory for replacement parts.

NOTE
A maximum of 8 luminaires may be daisy chained on a single circuit. See luminaire wiring diagrams.
WIRING INSTALLATION CHECKLIST

1. Verify sufficient quantity of Eaton’s STL thread lubricant is on conduit entries and that all unused conduit entries on the end caps are closed with lubricated plugs (see Figure 13).

2. Verify conduit is installed to at least five (5) full threads into the end cap conduit entries. Recommend approximately 1/8” bead quantity of Eaton’s STL thread lubricant on conduit entries.

3. Verify installed conduit is torqued to 42-52 ft.-lbs. (57-71 N-m) for 3/4” plug.

4. Verify supply wires are connected to luminaire wire leads per Figure 14A, Figure 14B or Figure 14C.

5. Verify all electrical connections are properly made and secure.

6. Verify all wires are routed correctly and are fully contained in the driver housing without any wires being pinched when the light engine fitting is rotated back into position. Re-attach driver cover to luminaire driver housing using the bolt tightening sequence in Figure 9.

7. Verify captive attachment screws are tightened to 23 in.-lbs. (2.6 N-m) and light engine fitting is in flush contact with driver housing.

WIRING DIAGRAMS

MAINTENANCE GENERAL

Important Notes: Branch circuit field wiring must be disconnected prior to initial luminaire installation or maintenance. Before performing any maintenance work with the luminaire enclosure open, the battery pack must be disconnected from the converter/inverter assembly by separating the latching connectors (connecting two white wires and  two black and red wires of battery). Also disconnect battery/converter connector (RedRed wires). See Figures 14A, 14B and 14C for connection location.

1. Disconnect the battery/converter connector during extended periods of power loss of more than 1 week.
2. If luminaire is out of service for more than 1 year, perform annual test procedure & replace battery packs as needed.
3. Perform visual, electrical and mechanical inspections on a regular basis. The environment and frequency of use should determine this. However, it is recommended that checks be made at least once a year. We recommend an Electrical Preventive Maintenance Program as described in the National Fire Protection Association Bulletin NFPA  No. 70B: Recommended Practice for Electrical Equipment Maintenance (www. nfpa.org)
4. The lens should be cleaned periodically to ensure continued lighting performance. To clean, wipe the lens with a clean, damp cloth. If this is not enough, use a mild soap or a common liquid cleaner. Do not use an abrasive, strong alkaline or acid cleaner. Damage may result.
5. Visually check for undue heating evidenced by discoloration of wires or other components, damaged parts or leakage evidenced by water or corrosion in the interior. Replace all worn, damaged or malfunctioning components, and clean gasket seals before putting the luminaire back into service.
6. Electrically check to make sure that all connections are clean and tight.
7. Mechanically check that all parts are properly assembled.
8. Check and re-torque all mounting hardware.
9. To prevent heat build-up, remove dust from the LED housing using a soft brush or air pressure.
10. Visually inspect status indicator (charging) indicator light monthly. It should be illuminated (when AC power ON). If indicator is flashing contact tech support.
11. Test the emergency operations of the luminaire at 30-day intervals for a minimum of 30 seconds. The LED load should operate at reduced illumination in case of power failure
12. Conduct a 90 minute discharge test once a year. The LED load should operate at reduced illumination for at least 90 minutes.

REPLACEMENT PARTS
(USE LISTED FITTINGS COVERED – LED DRIVERS, MOUNTING OPTIONS, LED LIGHT ENGINE)

Eaton’s Crouse-Hinds series Champ Pro Linear Emergency LED luminaires are designed to provide years of reliable lighting performance. However, should the need for replacement parts arise, they are available through your authorized Eaton’s Crouse-Hinds distributor. Assistance may also be obtained through your local Eaton’s Crouse-Hinds representative or the Eaton’s Crouse- Hinds Sales Service Department, 1201 Wolf Street, Syracuse, New York 13208, Phone 866-764-5454.

All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable. The accuracy or completeness thereof are not guaranteed. In accordance with Eaton’s Crouse- Hinds Division’s “Terms and Conditions of Sale,” and since conditions of use are outside our control, the purchaser should determine the suitability of the product for his intended use and assumes all risk and liability whatsoever in connection therewith.

Eaton’s Crouse-Hinds Division
1201 Wolf Street Syracuse, NY 13208 • U.S.A.
Copyright© 2022

References

• nfpa.org
• NFPA | The National Fire Protection Association

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