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1. 5 Tightenthe compression nutuntil the fibers are securely held by the ferrule assembly a DONOTuse ferrule mounting flanges for leverage when tightening assembly as they may break off Make sure fibers are not twisted or tangled b Pullonthe fiber bundle to verify fibers are held securely by ferrule assembly On some applications itmay be necessary to put a few wraps of electrical tape underneath the grommet to ensure a good grip c Ifyouareusing ColorContrast do not tighten the compression nut until the fibers are installed in the disk and itis snapped in place This allows the fibers to align without twisting 6 Install the fiber disk onto the ferrule assembly a Choose the correct fiber disk off the fiber disk tree according to the number of fibers The fiber range is on each disk For color contrast this is the total number of fibers on both sides of the division b Slide the fiber disk tapered end down over the fiber bundle Snap the fiber disk into the fiber disk support posts on the ferrule For ColorContrast slide the small bundle of fibers in first then the larger bundle c Check the position of the ferrule assembly The fiber disk Fiber Disk should be at least as highas the lower tier on the Photon Fiber Disk Generator Support Posts gt wif Ferrule ii E ACAUTION Mounting F off FI s Make sure there is enough slack in the cable s to be put in place There Di f r AQ s
2. Tools and Material Required Cable Stripper Crescent Wrench Hot Knife Cutting Shield Lens Tightening Tool Electrical Tape OptiFusion Gel GROMMET FLUSH WITH FRONT FACE 1 16 IN OF JACKET SHOWING 2 Add tape spacer compression nut and grommet 3 Add seal nut and tighten CHECK FOR AIR BUBBLES 6 Fillreservoir with gel 7 Slowly screw on lens cap P N 99293100 14 Rev J 2 24 10 AmerGlow Lens Assembly Installation Steps continued INVISIBLE GUNITE VINYL LINER LENS HOUSING LENS HOUSING BEFORE OR AFTER FACE PLATE 9 Hand tighten the retainer nut 4 e Holdtheseal nut stationary with your hand and rotate the compression nut using acrescent wrench e Ifyouuse channel locks to hold the seal nut be careful not to damage the O ring e Tighten the compression nut until the grommetis flush with the front surface of the seal nut for smaller cables or there is only one thread left showing on the compression nut for larger cables e Pullonthecompleted assembly to be sure cable does not move Seal Nut O ring Compression Nut Grommet select Lens O ring proper size for cable 1 Lens Retaining FIBERworks Lens Housing Spacer with O ring use Nut Invisible Gunite shown wih Invisible Gunite and Seal Nut Vinyl Liner Lens Housing Figure 6 Rev J 2 24 10 15 P N 99293100 5 Cutthe fiber Note This is the most critical step for a successful installation a Screw the Cutt
3. B OptiFusion Lens positioning with the Photon Generator centered at end of pool 1 AmerGlow 170 225 and 325 only with the lens positioned at the end of the pool a Forwhite ornearly white concrete fiberglass or vinyl pools OptiFusion lenses intended to illuminate the entire length of the pool are best placed in the shallow end wall or step as near the water surface as possible For light colored vinyl pools place the lenses in the deep end 18 in below water to adequately illuminate the hopper and slope Ifusing shadow fillers end light should be as close to water level as possible Whenever possible the lenses should not face directly towards the home or entertainment area Single AmerGlow 170 225 325 Center of end wall Dual AmerGlow 170 s or 225 s Each 2 to 3 5 feet from center line 4 to 7 feet apart C OptiFusion Lens positioning on the side of the pool with the Photon Generator centered on side of pool 1 AmerGlow 100 70 and 30 only with the lens positioned at the side of the pool a Avoid facing lenses directly towards home or entertainment area Lenses should be located and directed to offer uniform illumination ofthe entire pool allocating more light for areas with greater floor and wall surface area suchas the deep end Also see Light Transmission vs Distance table for more help The best lighting is achieved on the surfaces the lens is facing Depth of OptiFusion lenses intended to cast light less than
4. as shown in Figure 5 d Thecable stripper is directional ifit does not cut properly try moving it over and rotating in the opposite direction Make sure the cut doesn t spiral Once rotational jacket cut is made grasp the cable and pull stripper towards end of cable to split jacket along its length then remove jacket g DONOT damage any ofthe fibers Ifthe fibers are nicked they can break reducing light output h Practice on some spare cable a few times With a little practice you will be able to make good cuts with this stripper B Loading the fiber into the ferrule 1 Gatherall ofthe stripped cable ends together evenly and wrap tape around the fibers at the end a Fanthe fiber ends to remove any excess powder from between the fibers b Arrange the bundle so thatthe fibers from the primary pool spa underwater lenses or perimeter cable are mixed together and lie in the center of the fiber bundle Locate less important fibers on the outside of the fiber bundle Shinea flashlight from the lens back to the photon generator to help identify the fibers c Forcolorcontrast separate out the fibers for the smaller division A maximum of 60 fibers can be inserted here Itis easierifyou let the fibers from the smaller division extend a few inches past the others d Ifthetotalnumber of fibers is less than 200 then add additional fibers to the fiber bundle until the total number of fibers is either 100 or 200 These additional fibers should
5. level 2 Leveled base canbe secured in place with 3 8 in rebar angled through holes provided in corners of bottom flange Note Flat side of base is back of the Photon Generator where switches are located Locate this side away from line of site to the Photon Generator C Mounting to a poured concrete pad 1 Whatyou llneed Surface mounting kit P N 24000800 Ya in concrete anchors and screws or 3 16 in x 1 4in flat head Tapcons Masonry drill in or 5 32 in Hammer lt ce ee se Screw Driver or Nut Driver continued on page 1 1 Rev J 2 24 10 9 P N 99293100 Photon Generator Installation Steps a as detailed in Sec IV B and C Tools and Material Required Hammer Side Cutters Phillips Screwdriver Hacksaw or PVC Cutters Four 12 in lengths of 3 8 in Rebar or Rod ees JING 6 IN IN a 90 WINDOW DIMMER ELECTRIC CONDU INFRONT 6 H bracket for wood decks or concrete 7 Secure the generator with the screws provided P N 99293100 10 Rev J 2 24 10 2 Installingthe surfacemounting kit Set the H bracket in place on the backside of the conduit bundle b Make sure the template is located correctly with respect to the conduit and oriented so that the Photon Generator will be facing in the desired direction See the template at the back of this manual for correct conduit location c Markand drill the holes for the anchors or Tapcons d Secure the H bracket to the
6. N 99293100 Photon Generator Conduit Template Sub terrain Mounting Base Electrical DorE AmerGlow 170 225 C D E AmerGlow 12 30 70 A B C D E Surface Mounting Kit CCUG senine DorE AmerGlow 170 225 C D E AmerGlow 12 30 70 A C D E SAVE THESE INSTRUCTIONS 1620 Hawkins Ave Sanford NC 27330 800 831 7133 919 566 8000 Pentair Water 10951 West Los Angeles Ave Moorpark CA 93021 800 831 7133 805 553 5000 Pool and Spa 2010 Pentair Water Pool and Spa Inc All rights reserved This document is subject to change without notice Trademarks and Disclaimers FIBERworks Photon Generator AmerGlow Compool and Pentair Water Pool and Spa are trademarks and or registered trademarks of Pentair Water Pool and Spa Inc and or its affiliated companies in the United States and or other counties Jandy is a trademark and or registered trademark of Jandy Industries Inc Unless noted names and brands of others that may be used in this document are not used to indicate an affiliation or endorsement between the proprietors of these names and brands and Pentair Water Pool and Spa Inc Those names and brands may be the trademarks or registered trademarks of those parties or others P N 99293100 24 Rev J 2 24 10
7. be at least 6 inches long and arranged on the outside of the fiber bundle AWARNING Fibers outside the 400 fiber bundle diameter do not provide adequate light output for primary pool spa underwater lenses or perimeter cable Outer 200 fibers are intended only for accessory lighting For primary pool spa lighting and perimeter cable use only the center 400 fibers Failure to provide adequate lighting can result in swimming and diving hazards that can cause severe injury or death 2 Selectthe proper compression nut and grommet for the number of fibers see Table 2 3 Determine ifthe ferrule insertis needed inthe assembly See Table 2 Ifso remove the ferrule insert from the disk tree It is located between the 100 and 600 disks on the disk tree Rev J 2 24 10 21 P N 99293100 4 Slidethe compression nut grommet ferrule insert ifapplicable and then ferrule body onto the fiber bundle See Figure 10 Leave about 2 to 3 inches of fiber sticking out past the two posts on the top of the ferrule For ColorContrast the smaller bundle should extend an inch further about 3 to 4 inches Table 2 Number Compression Nut Grommet size indicated Ferrule Insert of fibers check inner dia on back except 400 located on disk tree and 600 grommet 100 Small D 70 yes 200 Small D 225 yes 200 300 Small D 225 yes 300 425 Small D 325 yes 425 500 Small D 400 small I D cylinder no 500 600 Large I D 600 large D cylinder no
8. cable as itis fed through a Keep the last foot ofcable on the lens side as straight as possible b Becarefulnot to damagethe lens assembly 6 Stop feeding the cable when one foot is left on the pool side a Makesurethe lens O ring and spacer O ring if applicable are in position and clean b Cleanthe O ring sealing surface on the inner flange of the lens housing 7 Continue to pull the cable until the lens assembly is in away from the seated position ACAUTION DO NOT snug the lens into place by pulling on the cable This may cause the cable to pull away from the lens and will impair performance of the OptiFusion system 8 Placethe lens retaining nut onto the lens and PUSH the lens into place 9 Handtighten the lens using the lens tightening tool until the O ring is seated a Forstandard gunite and fiberglass lens housings which do notuse the spacer and spacer O ring hand tighten 4 turn past the seated O ring position b ForInvisible Gunite and Vinyl Liner housings which use the spacer and spacer O ring hand tighten the lens retaining nut 2 turn past the O ring s seated position D Pulling or feeding bulk cable 1 Push the fishtape through the conduit In many cases AmerGlow cable may be fed through conduit without the use of fishtape 2 Attach the cable to the end of the fishtape using ductor electrical tape Cover the fibers completely with tape Pull cable through conduitusing electrician s lube
9. concrete pad with screws or Tapcons see Figure 3 SECTIONV Feeding or Pulling the AmerGlow Cable A What you ll need y Electrical Tape V Fishtape optional Vy Electrician s lube optional B Tips tricks and traps On pre OptiFused cable avoid manually bending the first 12 in of cable on the lens side This can disturb the factory termination and prevent maximum performance of the system Use electrician s lube on the cable to help it through the conduit Though not necessary it can make the task easier and quicker Cut conduit at Photon Generator to correct length 1 in above base before pulling cable Cover the end of the cable with electrical tape or similar tomakea pilottip This will make guiding the cable through the conduit easier This applies whether pushing the cable through from the pool side or pulling it with fishtape Atthe Photon Generator location after the cable is pulled and lenses are set seal the conduit around the cables with RTV silicone caulking or conduit seal kit 22002000 This will help keep debris out of the conduit during the rest of the installation and provide an added precaution to prevent water from entering the Photon Generator should the conduit develop a leak during its lifetime Leave about 1 foot of cable extending past the end of the lens housing at the pool only necessary if cutting and OptiFusing cable and lens on job location Once the cable is finished and the lens
10. for an electrical installation of this type SAVE THESE INSTRUCTIONS P N 99293100 2 Rev J 2 24 10 Table of Contents SECTION I Before You Begin Installation 1 0 cerita vide Aachen dep ere gach eeeseeanees 4 The Installers Ten Laws of FIBERWOrkKS 2 20002 2c2 sale ects bien bei dewe eb edeee ete 4 A The Pool Designer Salesperson s Ten Laws of FIBERworks 0 2000e ee eaee 5 B OptiFusion Lens positioning with the Photon Generator centered at end of pool 6 C OptiFusion Lens positioning on the side of the pool with the Photon Generator centered on side of pool nica tas unDiarinst ote en ve Pea atue 4 Rakha ht ddened pods 6 SECTION Running Conduit ss ecaa lacked eine Seo e pees E Sens 8 SECTION lll Installing Lens Housings avs ee eae Ya eee ewes Piers ed eee 9 SECTION IV Preparing to Mount the Photon Generator 0 00 0 eee cee es 9 SECTION V Feeding or Pulling the AmerGlow Cable 0 ccc c cece eee eee eees 11 SECTION VI AmerGlow Lens Assembly nunnan nnana unner rnrn ewe 12 SECTION VII Installing the Photon Generator n unanunua nearen 17 SECTION VIII Installing the Cable at the Photon Generator 0 00 c cece eee eee 18 Photon Generator Specifications Electrical Input V oltace jc cccenseactianscece 120 V 2 A CE units 240V 1A Power Consumption 006 Less than 250 Watts Mechanical Dimensions ies
11. in electrical conduit to run 4 18 AWG red black white and green or larger wires to each Photon Generator location see Figure 8 c Itis very important thatthe unit be properly grounded there is serious risk of electrical shock or electrocution otherwise The Photon Generator must be properly grounded Consult the National Electrical Code and all other applicable local codes and ordinances for proper grounding techniques Improper installation will create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock and may also cause property damage d Makesure the conduit comes up in the correct area in the front of the Photon Generator see Section IV for this information e Extend conduitup through the bottom ofthe Photon Generator at least six inches Once the Photon Generator is installed the conduit should extend one inch past the angled aluminum piece beneath the transformer D Running the conduit for AmerGlow fiber optic cable a Using the sizes determined above run the conduit from the pool wall to the Photon Generator location b Conduitnear the Photon Generator should be at least 4 in deep ifusing the sub terrain mounting base to mount the Photon Generator c Useonly electrical sweep elbows and 45 s DO NOT use plumbing 90 s or 45 s as they can damage the fiber optics or prevent pulling the cable d Thelens body shouldbe located accordin
12. 25 feet in white or nearly white concrete or fiberglass pools should be located approximately 1 3 of the distance between the water surface and the beginning of the transition from wall to floor e Place slightly higher in the 3 ft shallow ends to avoid hot spots on the floor In vinyl pools the shallow end lenses should be located 9 in below water e Lenses nextto the slope should be located 12 in below water e Deep end lenses should be located 18 in below water Note In many pools optimum lighting can be achieved with AmerGlow 170 225 or 325 cable s in the end and an AmerGlow 30 70 or 100 in the adjoining side wall illuminating the end wall where the AmerGlow 170 225 or 325 is located P N 99293100 6 Rev J 2 24 10 FIBER EQUIVALENT LIGHT TRANSMISSION at 10 ft AMERGLOW CABLE SIZES Cable 100 of Light Length fi a ae aes one D En fiber equiv Ae sae NE n E en 4 o amp oO ae e2 ol D a nN Re i D Q dS 151 145 139 O N Cc NPR TM oO O N w o gt a wo o vinle l amp u a la lA la co alIlOIRIOIlAIlSITaAlo sa N N co Table 1 This table shows the effect of longer cableruns on light transmission Longer cableruns have the same effect as cutting down on the number of fibers The first 10 is considered unavoidable and is used here as a standard for comparison AWARNING Provide adequate lighting to your pool for nighttime use The amount of light needed wi
13. CUTION This Photon Generator must be installed by a licensed or certified electrician in accordance with the National Electrical Code and all applicable local codes and ordinances Improper installation will create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock and may also cause property damage Disconnect all power before starting the installation process to all associated pool equipment Failure to do so may lead to severe electrical shock which can result in death or severe personal injury AWARNING Before installing this FIBERworks product read and follow all warning notices and instructions accompanying this light product Failure to follow safety warnings and instructions can result in severe injury death or property damage You are going to be using a sophisticated device which requires knowledgeable handling in order to insure its optimum performance Please do not touch anything until you have read and understood these instructions If you have any questions please call our service hotline Monday through Friday 7 30 a m to 4 30 p m 800 831 7133 AWARNING It is recommended that FIBERworks be installed by trained and certified FIBERworks dealers only This installation manual assumes that your Photon Generator will be properly installed in full accordance with the instructions provided the National Electric Code and any local codes applicable
14. FIBERworks Fiber Optic Cable Installation and Service Manual Underwriters Laboratories Inc C C Listed UI Model No s CE Model No s 20100100 20100208 20100200 20100408 20100300 20100608 20100400 20100500 20100600 Pentair Water Pool and Spa Inc 1620 Hawkins Ave Sanford NC 27330 800 831 7133 919 566 8000 Pentair Water 10951 West Los Angeles Ave Moorpark CA 93021 800 831 7133 805 553 5000 Pool and Spa Visit us on the Internet at www pentairpool com or www staritepool com Rev J 2 24 10 1 P N 99293100 IMPORTANT SAFETY INSTRUCTIONS When installing and using this electrical equipment basic safety precautions should be followed including the following READ AND FOLLOWALL INSTRUCTIONS 1 DANGER Toreduce the risk ofinjury do not permit children to use this product unless they are closely supervised at all times Check your local building codes before installation to ensure the Photon Generator light source is located at least the minimum distance from the pool that local codes require The electrical supply for this product must include a suitable rated switch or circuit breaker to open all ungrounded supply conductors to comply with Section 422 20 of the National Electrical Code ANSI NFPA 70 1987 The disconnection means must be readily accessible to pool and spa users but installed at least 5 feet 1 5m from the pool or spa water AWARNING RISK OF ELECTRICAL SHOCK OR ELECTRO
15. as needed 3 Leaveone 1 ft of cable extending past the lens housing and about one foot 1 above the Photon Generator mounting surface SECTION VI AmerGlow Lens Assembly A Whatyou ll need V OptiFusion termination kit P N 21005500 Contains cable stripper hot knife spare blades cutting shield lens tightening tool OptiFusion gel Cable Cutters Wire snips Channel locks Crescent wrench lt lt ee Electrical Tape P N 99293100 12 Rev J 2 24 10 B Preparing the cable NOTE There should be about 1 foot of cable sticking out of the lens housing at this point AWARNING FiberKnife reaches extreme temperatures Grasp only by the handle Failure to follow these directions can lead to severe burns 1 Pluginthe FiberKnife and set it on the stand provided Letthe knife warm up for 15 minutes This is especially important for larger cable sizes b Keep the knife out of the wind while warming as the breeze can cool it off The Photon Generator front cover can be used as a shield c Allowatleast5 minutes between large cable cuts for the knife to reheat 2 Usethecable stripping tool to strip back 1 in of the cable jacket ACAUTION DO NOT damage any of the fibers If the fibers are nicked they can break reducing light output e Practice on some spare cable a few times With a little practice you will be able to make good cuts with this stripper There is an extra blade inside the stripper hand
16. de angle Burrs on the edge of the cutting shield The FiberKnife is not warmed up enough Allow enough time between cuts for the knife to reheat and keep it out of the wind while heating it The blade needs replacing about every 15 20 cuts replacement pack of 3 blades P N 21005600 C Installing lenses 1 Wipe the fiber face with an Optic Prep Pad or a clean cloth to remove any residual powder Fiber Knife 2 Fillthe entire gel cup located on the inside of the lens with OptiFusion gel Blade untilit crests above the gel cup edge 3 Assemble the lens to the seal nut Make sure the lens and seal nut O rings are clean and in place b Holdthecompression nut witha wrench and hand tighten the lens onto the seal nut until lens bottoms out Keep the end of the cable straight during this step Cutting Shield P N 99293100 Figure 7 16 Rev J 2 24 10 4 Installthelensintothelens housing a Ifapplicable make sure the spacer and spacer O ring are in position and clean The spacer is marked This Side Toward Pool b Cleanthe O ring sealing surface on inner flange oflens housing c Feedorpull the cable until the lens assembly is about 1 in away from the seated position ACAUTION DO NOT seat lens housing by pulling on cable This may cause the cable to pull away from the lens and impair light performance d Place the lens retaining nut onto the lens and PUSH the lens into place e Hand tighten the lens u
17. dle the conduit together in the Photon Generator area Keeping the conduit together will help when preparing the cable later SECTIONIII Installing Lens Housings e FIBERworks lens housings are installed the same way regular water return fittings are installed ACAUTION Use only FIBERworks lens housings Other fittings will not seal conduit Each FIBERworks lens housing has a label identifying it as such Do not use excessive glue as the overflow may run onto the O ring sealing surface SECTIONIV Preparing to Mount the Photon Generator A Choose the right installation type from the two methods for installation of the Photon Generator 1 Forasimple quick installation youcan mountthe Photon Generator to the sub terrain mounting base included This allows the unit to be located away from the deck for example ina garden near the pool among some shrubbery etc Be sure the unit is situated such that the air vents are not going to be blocked by overgrowth The sub terrain mounting base can also be poured into the concrete deck or pad 2 The Photon Generator can also be mounted to the concrete pad or a wood deck requires surface mounting kit P N 24000800 B Installing the Sub Terrain mounting base see Figure 2 1 Ifconduithas already beenrun set mounting base over top of conduit to determine if the bottom flange or side arches need to be cut The top shoulder of the base should be at or slightly above finished landscape or deck
18. ete eees 18in x 10 in x 12 in Weioht fazi ns tendeccsghanasattinmnatiod 20 Ibs Mat rials oscoro sennik Powder coated steel aluminum high strength plastic This unit will accommodate up to 600 FIBERworks fibers Contents of the Shipping Carton This package should contain all of the following items Photon Generator Sub terrain Mounting Base Ferrule Kit FIBERworks Installation and Service Manual p n 99293 100 this manual Owner s Manual Warranty Registration Card Spare Light Bulb V LightBulb OrderForm To perform this installation you will need the following items lt lt ee ee Sf Electrical wire and conduit to connect main power FIBERworks cable and fittings as required OptiFusion termination kit p n 21005500 and the tools equipment listed in relevant sections of this manual Rev J 2 24 10 3 P N 99293100 SECTION I Before You Begin Installation The Installer s Ten Laws of FIBERworks DO NOT ATTEMPT INSTALLATION WITHOUT CERTIFIED TRAINING Take your time and be patient when terminating Rushing a 90 second FiberKnife 400 fiber termination can cause 30 loss of light Useonly prescribed OptiFusion tools FIBERworks FiberKnife and shield DO NOT USE MECHANICAL CUTTERS OR KNIFE BLADE HEATED WITH TORCH Make conduitruns as direct as possible plastic fiber loses 2 of light per foot see Table 1 Light Transmission Versus Distance 5 Whenhandling the cable do notbend final 12 in ofcable before le
19. former WHEN IN DOUBT CALL your FIBERworks Specialist or Technical Service at 800 831 7133 P N 99293100 4 Rev J 2 24 10 The Pool Designer Salesperson s Ten Laws of FIBERworks 1 Thecolor of fiber optics is fantastic but don tjust sell fiber optics sell FIBERworks More Light More Color More Friendly than other similar fiber optic systems from the World s Leading Manufacturer of Underwater Lights 2 Delight yourcustomers and get referrals Don tundersize neveruse fewer fibers or fewer lights than recommended 3 TheLonger the fiber optic cable the more it will cost and the less light it will transmit to the pool spa water feature or landscape light Distance costs 2 of light per foot see Table 1 Light Transmission Versus Distance 4 Choose your Photon Generator location s wisely Give your biggest cables the shortestruns Ifyou design never ending decks design a planter between 5 and 10 feet depending on code from the primary lens location 5 Colored surfaces absorb light The darker the surface the more light it will absorb Do not waste your customer s money on underwater fiber optics for dark surfaces They will not fully appreciate the dramatics of fiber optic colors Use Amerlites AquaLights or Hi Lites 6 The darkeryour pool surface the more dramatic will be perimeter FIBERworks Dark pools make great reflecting pools and fantastic perimeter FIBERworks pools For perimeter installat
20. g to recommendations in the Before You Begin Installation section Conduit should slope to that depth e Ifusingsmallerthan in conduit donot bush down z 1 in min within 2 in from rear oflens body f Usea12in minimum straight section of conduit behind the lens housing fa g For gunite pools the recessed cut back for lens Conduit housing should be atminimum 1 4 1in as shown in Figure 1 Dimension A shouldbe 1 in fora Plaster__ 4 FIBERworks Standard Gunite fitting and 1 in fora euaee FIBERworks Invisible Gunite fitting see Figure 1 P N 99293100 8 Rev J 2 24 10 Figure 1 h Atthe Photon Generator location leave at least 6 in of SUB TERRAIN MOUNTING BASE conduit above the anticipated sub terrain mounting base or deck surface and place tape over both ends of conduit JK PNISHED Lannscare The tape and extra length will help prevent debris from getting into the conduit until the cableisrun The conduit g CONDUIT ENTRANCE FOUR SIDES OR DECK LEVEL should be cut back to 1 in above the bottom of the Photon Generator mounting location just before the fiber optic cable is run does not apply to power supply conduit i Use the template on the back page of this manual to determine conduit location inside the Photon Generatorif youare installing ona poured concrete deck ona wood BEBAR STAKE HOLE deckor inthe ground j Foreithertype ofinstallation use duct tape or tie wrap to bun
21. hould be about 3 4 in of slack in the fiber bundle If not readjust the ferrule Ferrule Insert l y accordingly ifapplicable mes NA i Ferrule Body NOTE te This will provide ample fiber for future trimming of bundle required about every 5 years G 1 Place the Cutting Shield onto the ferrule assembly and thread on A until it bottoms out J 2 Holdthe cable and ferrule assembly so the support posts are at eempesee the top and bottom not on the sides keeping the cable and fiber bundleas straight as possible 3 Placethe FiberKnife blade against the Cutting Shield guide ring at a 10 15 degree angle starting at the top Support Post Figure 10 P N 99293100 22 Rev J 2 24 10 AIMPORTANT Press with a light to moderate constant pressure using the cutting shield ring as a guide IMPORTANT Do not rush allow 2 3 minutes to cut 600 fibers DO NOT use too much force Let the heat of the knife do the cutting DO NOT saw wiggle or rotate the blade back and forth On the larger fiber bundles it may help to rotate the handle side of the blade downward slightly a Easeup towards the end ofthe cut to keep the last few fibers from folding over 4 Remove Cutting Shield and wipe the fiber face with an optic prep pad or clean cloth This removes any residual powder AWARNING Shield may be hot Exercise caution when removing it Failure to do so could cause burns 5 Inspect the cut a Thecutshould be smo
22. i transformer with female connectors held by a tie wrap The white Yellow intemal power lead is for standard operation and the brown lead is for the bulb peal rele saver application See Figure 8 orkada b Disconnect the dummy male connector from the brown lead and Color whee switchi Brown lead from b ransformer then disconnect the two white wires ae male connector c Connect the brown lead from the transformer into the white wire eano from inside the unit inside of unit d Plug the dummy male connector into the white lead of the transformer Figure 8 e Make sure connections are secure and tuck wires back into place 3 For all models when not using dual remote switches or Compool type system a For this application there are only three electrical wires to connect Connect a minimum 18 3 wire with black to black white to white and green to green using wire nuts or crimps to make the connections 4 Converting the Manual Switch unit 20100200 to a Compool Jandy unit 20100400 a Locate the extra fused lead included in the ferrule assy bag Disconnect the extra male connector from fused lead DO NOT discard extra male connector b Facing the front of the unit with the front cover removed locate the color wheel switch connection yellow wires on the right inner wall of the Photon Generator tower See Figure 8 c Disconnect the yellow wires and plug the extra male connector into the yellow internal power lead for the c
23. ing Shield onto the seal nutuntil it bottoms out Atthis point only fiber should be sticking out past the edge of the cutting shield Ifjacket or grommet is sticking out disassemble seal nut assembly and adjust the grommet position b Holdthe cable atthe seal nut keeping the cable straight ACAUTION DO NOT use too much force you will only damage the FiberKnife and or your cut Let the heat of the knife do the cutting DO NOT saw wiggle or rotate the blade back and forth On the larger cables it may help to rotate the handle side of the blade downward slightly Place the blade against the cutting shield at a 10 15 degree angle see Figure 7 Press with a light to moderate constant pressure using the cutting shield ring as a guide Ease up towards the end of the cut to keep the last few fibers from folding over 6 Remove the Cutting Shield Shield may be hot Exercise caution when removing it Failure to do so could cause burns 7 Inspectthe cut a Thecutshouldbe smooth and flat with no visible lines or surface bubbles When training and performing your first cuts using a small magnifying glass can help see imperfections that may be difficultto see with the naked eye b A good professional cutis critical to the performance of the fiber optic system c There are several things which can cause a bad cut The cable jacket was not completely stripped back Sawing or wiggling the blade during cutting or incorrectbla
24. ions over200 consult your FIBERworks Specialist 7 FIBERworks powerfully illuminates the wall and floor surface toward which the lens is pointed modest illumination is on the wall which holds the lens AmerGlow 12 30 70 or 100 cables make great step lights and shadow fillers when directed toward or across the wall holding the AmerGlow 325 225 or 170 cables 8 Theprimary light ofa lens spreads at a 70 degree angle 35 degrees from the lens center line You can angle the Invisible Gunite Lens Body in the wall before shotcrete or gunite by tying the 1 in PVC pipe to the rebar and staking the back end at the angle desired 9 Alwaysuse Certified FIBERworks Installers A rushed or poor installation can kill performance by 30 Schedule training as soon as possible 10 WHEN IN DOUBT CALL Technical Service at 800 83 1 7133 OR fax a scale drawing to 919 566 8924 Rev J 2 24 10 5 P N 99293100 A FIBERCAD Design Assistance for Pools amp Spas For assistance in designing your fiber optic pool or spa lighting fax a FIBERCAD information form and scale drawing to 919 566 8924 Ifdesigning your own lighting layout itis critical to keep the Photon Generator as close to the pool as possible less than 15 is desirable and cable runs as short as possible to maximize light output see Table 1 Light Transmission vs Distance Do not attempt to light a pool larger than 24 ft x 42 ft or 1 000 sq ft with a single Photon Generator
25. is installed at the pool end you should have 20 in to 24 in extending up above the Photon Generator mounting location This will allow easier installation into the Photon Generator Also a few extra inches in the fiber bundle will accommodate fiberre termination ifthe fiber ends were to become damaged over years of service Additionally it allows for later addition of fibers for landscape or pool lighting Ifthe lens assembly and or Photon Generator are not to be installed immediately tape the ends of the cable Mounting surface to protect the fiber bottom of Photon ACAUTION Generator Know your cable length do notunderestimate the cable length required Allow 20 in extra forpre OptiFused cable and 24 in for bulk cable from pool wall to bottom of Photon Generator Figure 3 Screws Rev J 2 24 10 11 P N 99293100 C Pulling or feeding pre OptiFused cable 1 ForStandard Gunite lens housing and Fiberglass lens housing remove the spacer and spacer O ring using diagonal cutters 2 Removethe reminder tag from the cable 3 Pushthe fish tape through the conduit from the Photon Generator side NOTE In many cases AmerGlow cable may be fed through conduit without the use of a fishtape 4 Attachthe cable atthe poolside with duct or electrical tape making sure to cover the open end of the cable 5 Reelup fishtape while second person pushes the cable from the pool side applying electrician s lube on the
26. le a Adjustthe stripper and practice a few times on an extra piece of cable if you haven t used it before b Adjust the cutting depth by turning the black knob on the end of the cable stripper c Pushthe spring tension guide open with thumb and place stripper on cable as shown in Figure 4 d Rotate the stripper around the cable with the black knob toward opening as shown in Figure 5 e Thecablestripper is directional ifit does not cut properly try moving it over and rotating in the opposite direction f Oncejacket is separated pull stripper towards end of cable to remove jacket g Fanthe fiber ends to remove the excess powder from them 3 Ifyouare installing an invisible gunite or vinyl liner lens housing place the spacer and spacer O ring onto the cable the direction is indicated on the spacer 4 Assemble the seal nut see Figure 6 Wrap electrical tape around the end of the fibers b Slidethe compression nut onto the cable with the threads toward the end c Choosethecorrect grommet size and slide it onto the cable until 1 16 in past the edge of the jacket The cable size is molded onto the back of the grommet d Straightenthe cable coming out of the lens housing and try to keep it straight from this point on e Placethesealnut overthe grommetand tighten compression nut continued on page 15 Rev J 2 24 10 13 P N 99293100 AmerGlow Lens Assembly Installation Steps as detailed in Sec IV B
27. ll vary with the size and shape of the pool This may require additional lighting sources Failure to provide adequate lighting can result in swimming and diving hazards that can cause severe injury or death Consult your local building department or a lighting professional to determine lighting requirements Rev J 2 24 10 7 P N 99293100 SECTIONIL Running Conduit A Generalconduit tips e Use electrical sweep elbows and 45 s or heat bend PVC pipe DO NOT use plumbing 90 or 45 elbows Using the right conduit and fittings will allow the cable to be fed much easier and will prevent damage to the fiber optics e Userigid PVC pipe or SMOOTH ID flexible PVC for all cable runs Flexible pipe can be used but is not recommended for this type of installation because ofits high friction walls e Make yourjob easier use electrician s lube when feeding cable B Choosing the best size conduit for the job a For AmerGlow 325 225 or 170 use 1 in or larger rigid PVC conduit 1 in is preferred b Use in or larger conduit for AmerGlow 100 or 70 c Use in or larger conduit for AmerGlow 30 or 12 C Electrical conduit requirements a Formanual operation at Photon Generator remote control or single remote toggle switch operation use 2 in electrical conduit to run 3 18 AWG black white and green or larger wires to each Photon Generator location b For dual remote toggle switch or automated operation Compoo etc use
28. may also cause property damage 1 Determining when touse the bulb saver feature a Thebulbsaver feature is for installations located in areas with line voltage consistently higher than 120 Vac Check the line voltage at the electrical panel preferably at night with a voltmeter to determine if this feature should beused All units come with the transformer connected for normal operation b Thebulb saver feature may also be used on installations with 120 Vac or lower line voltages to increase the average bulb life Please note that using the bulb saver feature on pools with standard 120 Vac input voltage will decrease the nominal light output by about 15 Rev J 2 24 10 17 P N 99293100 AWARNING Connecting the bulb saver feature on installations with 120 Vac or lower input voltage can significantly reduce the nominal light output from the Photon Generator Be sure the fiber optic system has been designed to adequately light the pool with the reduced output from the Photon Generator Failure to provide adequate lighting can result in swimming and diving hazards that can cause severe injury or death 2 Connecting the bulbsaver feature a Facing the front of the unit with the front cover removed locate Connections shown for normal operati eae bled from fact the transformer connection on the right inner wall of the Photon Penna ripen cre Right inner wall of Generator tower There are two wire leads coming from the aean Gener
29. ns 6 Pushlens and final 1 in of cable into lens body DO NOT PULL IN 7 Bottom of Photon Generator should be at or slightly above grade and protected from grass 10 Locate the Photon Generator above water level whenever possible Ifraised water features are being lit be sure the end of the conduit inside the Generator is filled with RTV other suitable sealant or conduit seal kit 22002000 and locate the Generator so water will drain away from it and not accumulate inside of or around the Photon Generator This will prevent water from flooding the electrical portion ofthe unit Make sure you have mounting accessory of choice either the Sub terrain Mounting Base or Surface Mount Kit PROPER TERMINATION AT PHOTON GENERATOR see Photon Generator Installation Steps a Firstmechanically cutall cables even to top of Photon Generator b Strip all cable jackets to 3 in or 4 in above bottom of Generator c SANITY SAVER onewrap of electrical tape over fiber bundle end d Install ferrule and tighten with 2 3 in of fiber extending out of fiber disk see Figure10 e Hotknife cut Hold blade angled at 15 degrees as if you were cutting cream cheese Don t stop and restart but rather keep continuous light pressure Don t saw or wiggle knife Ease up pressure as you come to end of cut f Besure ferrule is fully rotated and secured by ferrule screws g Wrapelectrical tape ortie wrap around bundle at angled aluminum piece under trans
30. olor wheel d Connect the fused lead to the internal yellow lead for the color wheel switch Tuck the fuse into unit next to the other power fuse e The two black power leads are labeled 1 for power 2 for color wheel f Both switches must be in the on position in order for the unit to operate from the remote switches 5 For Compool type automated systems or dual remote switches Pin eee a The Photon Generator has four loose wires to connect one white black 1 and black 2 and one green Please refer to your pool controller s manual for more information on the proper wiring and use of that equipment The main power and color wheel motor of the Photon Generator are controlled by two auxiliary relay circuits in the power Note Connections between Power Center and Remote are for illustration only Refer to Manual center Figure 9 shows how to wire up f for proper connection of p these components the unit on both ends gt s oc x 3 lt b Refer to the pool controller manual to Line Bik Neutral Wht determine which buttons on the controller operate the two relays Figure 9 Continued on page 21 P N 99293100 18 Rev J 2 24 10 Ferrule Assembly Installation Steps as detailed in Sec VIII A D Tools and Material Required V Cable Cutters V Cable Stripper V CrescentWrench V HotKnife V PhillipsScrewdriver V Cutting Shield y Electrical Tape ll TAPE OVER THEEND _ OF THE BONE aN
31. oth and flat with no visible lines or surface bubbles When training and performing your first cuts use ofa small magnifying glass can help see imperfections that may be difficult to see with the naked eye b A good professional cutis critical to the performance of the fiber optic system There are several things which can cause a bad cut e Sawingor wiggling the blade during cutting e Holding thebladeatan incorrect angle e Burrson the edge ofthe cutting shield e TheFiberKnife is not warmed up enough Allow enough time between cuts for the knife to reheat and keep it out of the wind while heating it e The blade needs replacing about every 15 20 cuts Pack of 3 blades P N 21005600 D Install the ferrule assembly into the Photon Generator 1 Twistlock the ferrule assembly into the hole and the retaining screws under the Photon Generator light bulb 2 Besurethe ferrule is securely against both screws and tighten the retaining screws e The ferrule body shouldbe centered in the mounting hole The alignment of the ferrule assembly is CRITICAL to the performance of the fiber optic system 3 Makesurethe ferrule is not being pulled sideways by the cable 4 Fillthe cable conduit ends with silicone oruse conduit seal kit 22002000 to prevent water from entering or leaking from the conduit E Place curved metal front onto Photon Generator and secure with the four black 6 screws F Test functionality ofunit Rev J 2 24 10 23 P
32. r KEEP FINGERS OFF EARS 5 rT 6 Selectthe correct numbered fiber disk 7 Snap disk into ears Rev J 2 24 10 19 P N 99293100 Ferrule Assembly Installation Steps continued TOJALLY COVER THE EAR I a m FIBER front cover 14 Install front cover P N 99293100 20 Rev J 2 24 10 A note about FreedomSynch Photon Generators 20100600 20100500 The wiring for these units is exactly the same as for all other Photon Generators All synchronization is self contained within the unit s electronics and is locked to the 60 Hz AC power line Please refer to the Owner s Manual for proper operation of these models SECTION VIII Installing the Cable at the Photon Generator A Preparing and installing the cable AWARNING FiberKnife reaches extreme temperatures Grasp only by the handle Failure to follow these directions can lead to severe burns 1 Plugin FiberKnife and allow to heat for 15 minutes out of the wind The Photon Generator front cover can be used asa shield 2 Cutallthe cables with cutters to top of Photon Generator 3 Use the cable stripping tool to strip back cable jacket 3 to 4 in above the Photon Generator base Adjust the cutting depth by turning the black knob on the end of the cable stripper a b Push the spring tension guide open with thumb and place stripper on cable as shown in Figure 4 c Rotate the stripper around the cable black knob toward opening
33. sing the lens tightening tool until the O ring is seated e ForStandard Gunite and Fiberglass lens housings which do not use the spacer and spacer O ring hand tighten turn past the seated O ring position e For Invisible Gunite and Vinyl Liner housings whichuse the spacer and spacer O ring hand tighten the lens retaining nut 2 turn past the O ring s seated position FIBERworks makes your job easier For vinyl liner pools the lens is sealed in the lens body before the liner is installed You do not need to install the seal plate and cut your liner until the pool is completely filled SECTION VII Installing the Photon Generator A Mounting the unit 1 Sealthe conduitaround the cable with RTV silicone or conduit seal kit 22002000 2 Remove the four black 6 screws securing the curved front cover of the unit and set aside ina secure location 3 Remove the front cover 4 Secure Photon Generator with appropriate hardware provided with surface mounting kit or sub terrain base Do not over tighten screws B Wiring the Photon Generator AWARNING RISK OF ELECTRICAL SHOCK OR ELECTROCUTION This Photon Generator must be installed by a licensed or certified electrician in accordance with the National Electrical Code and all applicable local codes and ordinances Improper installation will create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock and

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