RapidLED CREE CXB3590 Triple COB LED Retrofit Contents Overview... 1 Attaching LEDs to the Heatsink... 1 Wiring the Driver to AC Power... 2 Wiring the driver to the pucks... 4 Fan Installation... 6 Finishing Up... 7 Overview As with any type of lighting retrofit, there are many dangers, difficulties, and pitfalls that may occur. The Rapid LED CXB3590 retrofit should only be attempted by people familiar with AC/DC power and wiring, electronics, LEDs, LED Drivers, series circuits, etc. If you are uncomfortable with or inexperienced at any of the prerequisites required for this retrofit, you should not attempt this retrofit. Attaching LEDs to the Heatsink We need to apply thermal grease to the back of each COB and then attach it to the heatsink. Thermal grease ensures proper thermal conductivity of heat away from the LED into the heatsink. A very small dab of grease on the back of each COB is all that is necessary. More is NOT necessarily better. Too little will lower conductivity and too much will create a mess. A thin layer works best. The photo below is about how much you should use. 1
The heatsink has several T slots in it. Each COB is held on via two nuts/screws and we found it easiest to use two different t slots: one at the top of the COB and one at the bottom (see below). We suggest sliding in three nuts into each of the two t slots, one per COB. Make sure you secure the screws into the nuts that were previously inserted into the slots. To use the Ideal solderless connector properly, please make sure the polarity is lined up correctly. You will see a small + on the Ideal connector, make sure that is aligned with the + pad on the CXB3590. See picture below for details. *****NEVER APPLY POWER TO THE LED DRIVER BEFORE ALL WIRING IS COMPLETE ***** Wiring the Driver to AC Power The AC Line and Neutral, or ACL and ACN wires, which are brown and blue, connect to the power cord included in our kits. Strip the white and black wires of the power cord and attach them to the blue and brown wires on the driver with the included moisture resistant wire nuts. Order is not important because AC current alternates. Next, strip the green (ground) wire on the power cord and attach to the GND/Green wire on the driver like you did with the ACL/CAN wires previously. Obviously, 2
this step is dangerous because you are working with 110 or 220VAC. Make sure nothing is plugged in and have a licensed electrician assist you with this step. There are 4 output wires on the HLG 240H C2100B driver as in the below photo. The dimming wires, DIM + (blue), and DIM (white), simply hook up to the respective ports on your controller or dimmer/potentiometer (aka knob). The B series driver is compatible with a 0 10V analog or 10V PWM controller. If you do not have a dimming circuit or controller you can simply cap off the dimming wires with wire nuts to run at max current (2.1A). If you are using a dimmer, do NOT exceed 10V or you risk damaging the dimming circuitry. A 1V reference voltage will light the LEDs to 10% brightness, whereas a 10V reference voltage will light the LEDs to 100% brightness. For any questions on dimming or to purchase dimming accessories please contact us at staff@rapidled.com, or check our website under the Dimmers category. If using the HLG 240H C2100A driver there are only 2 output wires, red and black with no dimming wires. There is however a potentiometer on the bottom right hand corner of the case. This 3
screw/potentiometer allows you to manually adjust the current from a minimum of 1.05A to a maximum of 2.1A. The factory default setting will be 2.1A. Wiring the driver to the pucks After the pucks have been installed we will need to attach the driver s output wires (red and black) to the CXB3590 pucks. The Ideal connectors allow you to push in wire directly to the connector itself, all without soldering as long as you strip off ¼ 5/16 off the end of the wire. To begin we will wire the red (LED+) wire from the driver to the + solder pad on the first CXB3590. We ll use a wire nut to connect some bulk wire for additional reach since the driver wires are quite short. 4
We will wire the remaining COBs in series. Since we are wiring a series circuit (wired + to ) we will begin with the pad on our first CXB3590. We connect the to the + on the second CXB3590, then repeat between the second and third COB. We will be return from the pad on the third CXB3590 to the driver s black (LED ) wire. 5
Fan Installation The heatsink has two holes drilled for the fan. Use the included screws to secure the fan to the CNC d fan pocket on the back of the heatsink. Next, you ll need to cut off one end of the included 12V adapter. Peel apart and strip back both wires. The wire with the white dashed line is positive, and the solid black wire is negative. No Dashes Indicates Negative AC Adapter Wire White Dashes Indicate + (positive) AC Adapter Wire 6
Use the included grey wire nuts to connect the fan s + (red) wire to the adapter s + (white dashes) wire. Do the same for the fan/adapter s negative wires. Ensure the fan is always running when the COB LEDs are on to prevent overheating. Finishing Up After all of your wiring is complete power it up and enjoy! 7