For Con-Tech Lighting Magellan Low Voltage Flexible Track System

Con-Tech Lighting’s Magellan Low Voltage Flexible Track system has a 25 AMP capacity and is rated for use at 12V (300W
capacity) or 24V (600W capacity). Track sections may be cut in the field, and polarity is not an issue with this low voltage
system. Utilize a wide variety of fixtures, track lengths, accessories and transformers to customize your lighting plans.
Magellan Low Voltage Flexible Track is versatile. It can be powered with remote or surface mounted electronic or magnetic trans-
formers. All electronic transformers have auto-reset electronic short circuit, thermal cutoff and overload protection. Wattage
overload protection resets itself automatically when the wattage correction is made.

Assembled MAGELLAN Low Voltage Flexible Track System Magnetic

Low Voltage
Transformer

Ceiling Max. 15"

Connector

Max. 2-1/2 Ft.

Track Connector

Power Feed

Track Section

Track Fixture
(Direct Mount)
End Cap

Transformer Usage
Transformer size should be determined by the number of fixtures on each circuit (include any possible planned additions). 1996 NEC allows for
25 Amp max per circuit for systems 30VA or under. On 12V systems, the max is 300W per circuit. On 24V systems, the max is 600W per
circuit. Con-Tech transformers are sized to carry the full rated load. No downsizing is required. Caution: Do not load beyond rated capacity. A
built-in magnetic circuit breaker is provided on the 12 or 24 volt secondary circuit. The transformer must be installed in an accessible location
to allow for resetting of the breaker in the event of overload. Electronic transformers have built-in overload protection. The use of 10 gauge
conductors between the transformer and power feeds is recommended. Note: Maximum allowable voltage drop should not exceed 5%.
Sufficient wire size should be maintained in order to provide a proper operating voltage to all lamps.
Transformers/Voltage Drop Chart for Low Voltage Power Systems
When voltage and lamp brightness at the beginning of an illuminated section (close to the transformer) are higher than the voltage and lamp
brightness at the end, the difference is known as “Voltage Drop.” For a proper low voltage lighting system, circuit runs must be of sufficient
size wire to maintain a proper operating voltage to all lamps. Maximum allowable voltage drop should not exceed 5%.
Electronic Transformers
Maximum wiring distance (from remote transformer to start of track):
12' (Max.*) with AC Electronic Transformer (use minimum 10 ga. wire)
40' (Max.*) with DC Electronic Transformer (use minimum 10 ga. wire)
These distances may be extended with thicker gauge wire.
These transformers may be dimmed with dimmers specifically designed for use with Low Voltage Electronic Transformers. All electronic
transformers offer auto-reset short circuit protection, overload protection, and thermal cut-off at 257°F. These electronic transformers will not
operate without a minimum 30% load. UL Listed (UL 2108 compliant)
Magnetic Transformers
Maximum distance with Magnetic Transformer should not exceed 40.'
These transformers may be dimmed with dimmers specifically designed for use with Low Voltage Magnetic Transformers. High reliability with
magnetic circuit breakers. Primary 5% boost tap provided to compensate for voltage drop on long runs of 20' or more. These UL Listed (UL
2108 compliant) transformers will operate with any load.

WIRING DISTANCE IN FEET

REMOTE TRANSFORMER TO START OF TRACK Ampere Wire
Capacity Gauge
Low Voltage Transformer #10 GA #8 GA #6 GA #4 GA
Output Wattage Wire Wire Wire Wire 25 10
12 Volt 150 Watt 23' 36' 57' 91' 35 8
12 Volt 250 Watt 14' 21' 34' 55' 50 6
12 Volt 300 Watt 11' 18' 28' 45' 70 4

All specifications subject to change without notice.

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 For Con-Tech Lighting Magellan Low Voltage Flexible Track System

Ceiling and Wall Connectors

Connectors include a 15/16" flange with a two-piece plastic insulator
washer (external)/insert (internal), allen wrench, concrete anchor 8-32
brass nut and wood screw. (Figure 1) The maximum distance allowed
between ceiling connectors is 26". For sloped ceiling applications, a Concrete Wall Anchor
sloped ceiling adaptor is available.
On longer ceiling drops, use cable ceiling connectors. The cable has
crimped metal sleeves on both ends that are held in place by side 1.5mm
Insulator Washer
Allen screws in the threaded brass fittings. To adjust cable length, cut with
side-cutting pliers from only one end, turn the end over for 1/4" and insert Track Support Flange
the folded over cable into the center hole of the threaded brass fitting.
Lock the cable down with the 1.5mm Allen screw. Thread the brass fitting
into the ceiling flange so that no brass threads are showing.
Solid Surface Installation Wood Screw
The surface flange can be mounted to various surfaces (ceiling or wall).
For wood surfaces, use 1/8" drill bit for the wood screw included. In
concrete surfaces, use a 7/32" drill bit for the included concrete anchor.
Drywall Installation
For installation into a drywall surface, use a 1/8" toggle bolt anchor (not
included) which fits through the plastic insulator of the ceiling flange. A
1/2" hole should be drilled into the drywall to properly insert the 1/8" T-Bar Ceiling
anchor toggle wings. Toggle bolt anchors are available by others. T-Bar Mounting Clip

T-Bar Mounting
Use Con-Tech’s LA-1 15/16" Grid Stuf Type T-Bar Mounting Clip with #8-32
Insulator Washer
x 5/8" stud (Figure 2). Insert the stud through the ceiling flange and
insulator. Attach the nut to the #8-32 stud and lock down using a straight Track Support Flange
blade screwdriver. Upon completion, attach the assembly to the proper
location of the T-Bar ceiling. Care should be taken to add sufficient support
wires to the suspended ceiling to carry the additional weight of the
Magellan Flexible Track System. Barrel Nut

Mounting of Track Support Stems

After mounting the flange in either a solid surface or a T-Bar ceiling, the
support stem can now be attached (Figure 3). Screw in the vertical stem Track Support Flange
into the support flange, so that no threads are showing and tighten
securely. Loosen the 1.5mm Allen screw in the track connector and rotate
the lower portion of the stem assembly to align with the track section. Support Stem
Remove the stem cap and insert the track into the slot of the support
stem. Attach the stem cap loosely over the track and onto the stem
support. Adjust the track position as desired, then tighten all stem caps 1.5mm Allen Screw
and 1.5mm Allen screws securely. Max. 10 lbs. loading for stem.

Stem Cap

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 For Con-Tech Lighting Magellan Low Voltage Flexible Track System

Layout and Track Installation Procedure

Rail Shaping
Magellan layouts may be made using straight or curved track sections,
joined by conductive or non-conductive connectors (Figure 4). Curved
track sections may also be used to create arc, serpentine, round, or any
other configurations in the horizontal plane only. A Standard Curving Max. Angle: 25°
Machine (CRS320) is available to curve the track to your desired radius in
gradual measures. Over tightening or quick radical curves can remove the Min. Radius:
anodization from the track. Con-Tech Lighting can curve the 4' rails at the 12-1/2"
factory to your specified radius for an additional charge.
Circular bending capacity Angular bending capacity
Track Sizing/Cutting of track: 5 CYCLES of track: 1 TIME
Mark the track where it should be cut (if required). Cut the track with a fine
tooth (32T) hacksaw blade. Smooth off any burrs with a fine file or rasp.
Conductive connectors require that the track should have 3/4" the
anodization removed at the track ends, on all sides (Figure 5).

Mounting/Connecting Track Max. distance

Layout the Magellan design on the floor and connect the tracks together. between supports:
Align the mounting points on the ceiling using a plumb line or laser device. 2-1/2 ft.
Install all the support stems and power connections on the ceiling. Starting
at the power connections, begin with a single Magellan track piece and
attach it to its designated support(s) and/or power stem(s). Tighten all
Allen screws and suspension tabs.

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Install the connectors that the adjoining track will be attached to. The
Conductive and Non-conductive Connectors have a 3mm Allen screw that
must be tightened after placing the two tracks in the connector (Figure 6).
Conductive connectors require that the track should have 3/4" the
anodization removed at the track ends, on all sides. If using the Angular
Connector, tighten the (8) 2mm Allen screws and the (2) Philips screws on
top and bottom to lock the angle (60° to 300°) after the two pieces of
track are in the connector. The “T” Connector has (12) 2mm Allen screws,
the “X" Connector has (16) 2mm Allen screws that need to be tightened
after track pieces have been inserted. To lock proper angles, tighten the
Philips screw on the connector.
Bring the second track into position and attach it to the first track with the Remove 3/4" of anodization for
proper connector and/or power source. Secure the second track to the conductive connections.
ceiling support(s) and tighten all Allen and Philips screws. Repeat this
procedure until all of the track has been installed.
When finished, secure each end of the track run by installing the included
Track End Caps to each uncapped track end piece.
Once all the Magellan track has been installed, ensure that all

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connections and Allen screws are tightly secured. Never attempt to
raise an assembled layout or multiple pieces of track to the ceiling
as a single piece. Damage to the system may occur. Be sure that
POWER IS OFF when tightening during routine maintenance.

Track Connector

Track End Cap

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Power Stem Installation Procedure
Power Stems are available in fixed and adjustable lengths with canopy
(Figure 7); transformer sold separately. An Allen wrench is included for
tightly securing all Allen screws. Feed Rating: 12-24V, 25A.
Power Stem Mounting at the Junction Box
On the power stem assemblies, bring the 12 or 24 volt current to the 4"
round junction box. Attach the mounting bar to the junction box with (2)
#8-32 screws. The mounting bar has (2) Philips screws for holding the Fixed Power
canopy to the junction box. Connect the black lead wire from the power Stem Canapy
stem to the low voltage secondary wiring from the remote transformer.
Slide the canopy over the mounting bar side screws and twist until in the
proper place. Tighten the (2) Philips screws for the canopy. Adjust the length
of the power stem (if necessary) and lock into place with (2) 1.5mm Allen
screws (Figure 8).
Adjustable Power
Changing Power Feed Wire Length for Surface Transformers Stem Canopy
On the Power Feed Assembly, first attach the two wire leads to the surface

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transformer. Make sure there is enough wire to make the correct placement Low Voltage
on the track. Additional lengths of feed wire can be ordered from Con-Tech Feed From
Lighting. Remove the existing wiring from the Power Feed Assembly by Remote
loosening the (2) 2mm Allen screws on the side of the hub. Take the correct Transformer
length of the feed wire and insert the wire into the hub feed points. Tighten
the (2) 2mm Allen screws.
Mounting the Track to the Power Stem
Loosen the (2) Philips screws on the bottom of the power stem. Slide the
track through the power stem to its proper position. Tighten (2) Philips
screws on the bottom of the power stem. Then tighten the (2) 2mm Allen
screws on the top and bottom of the power stem hub assembly (Figure 9).

(2) 1.5mm Allen Screws;

(1) on each side of
adjustable stem

9 A B

C D

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Surface Mount Transformer Installation Procedure Junction Box
Surface Mount Transformers are to be used with Power Feeds. The (4" Round)
transformers are a 300W Magnetic or a 300W Electronic model. Both G N
housings cover a standard octagonal ceiling box. H
Surface Mount Canopy with Built-In 300W Magnetic Transformer
Part number CRS318. This transformer can be installed anywhere along the
system. Dis-assemble the transformer before mounting to a recessed 4" Universal Circuit
Mounting Plate Breaker
round junction box. Attach the universal mounting plate to the junction box
with (2) #8-32 screws from the box. Feed the three-conductor wire sleeve
through the center hole. Connect the wires properly. Attach the transformer
housing to the universal mounting plate with (2) Philips screws. (Figure 10)
The transformer housing has two keyhole slots for the Philips screws. The
screws should be attached to the universal mounting plate. Install the
transformer cover plate with the center slotted screw. The two wires from
the Power Feed can now be inserted into the bottom terminals. Ensure the
screws are well tightened on the terminals. (Figure 11)
Surface Mount Canopy with Built-In 300W Electronic Transformer

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Part number SA54T. Attach the universal mounting bar to the 4" round
junction box with (2) #8-32 screws from the box. Connect the 120V primary
leads (black/white) from the transformer to the supply wires along with the
ground wire. Slide the Power Feed conductors through the rubber grommet
and transformer. Connect the Power Feed conductors to the blue secondary
(12V) conductors from the transformer. Make sure the transformer heat
sinks are properly positioned around the wires and above the electronic
transformer. Slide the canopy assembly to the ceiling and align the mount-
ing bar screws with the canopy side holes. Tighten the screws to the mount-
ing bar. (Figure 12)
Connecting Flexible Track to Power Feed
Loosen the top Philips screws on the Power Feed and slide the Magellan
track through the power feed to its proper position. Tighten the (2) Philips
screws on the top of the power feed. Then tighten the (2) 2mm Allen screws
on the top and bottom of the power feed hub assembly. (Figure 13)

12
Junction Box
(4" Round)

H N
G

13
A B

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Fixture Installation Procedure
After the fixture is assembled, attach to the Magellan track using the
suspension tab. Tighten the cap in order to make good electrical contacts.
The two points in the suspension tab needs to pierce the anodized finish of
the track. Low voltage systems carry high amperage; high amperage
through loose connections can cause arcing and high temperatures that
could damage the entire system. Aim the fixture according to application.
(Figure 14)

IMPORTANT SAFETY INSTRUCTIONS:

• Read all the instructions before installation. Save instructions for later use.
• Turn off power at fuse or circuit breaker box before installation or before doing
any maintenance work.
• Product must be grounded to avoid potential electric shock and any other
potential hazards.
• Product must be mounted in locations and at heights and in a manner consistent
with its intended use, and in compliance with National Electrical Code and local
codes. Use of accessory equipment is not recommended.
• Installing contrary to instructions may cause unsafe conditions.
• Ensure all allen screws are properly tightened (top and bottom).
• Caution: to reduce risk of fire and electrical shock, use only fixtures and fittings
intended for use with the Con-Tech Magellan Low Voltage Flexible Track System.
• Do not use any wire smaller than #10 gauge copper for the secondary feed. The
track is rated for 25A capacity (300W at 12V or 600W at 24V).
• Intended to be connected only to 12 or 24 volt secondary wiring from a UL listed
transformer supply. Please do not exceed the nominal supply voltage.
• Do not block light from the trim aperture, in whole or in part, as this may cause
unsafe conditions.
• Warning: Risk of fire. Most dwellings built before 1985 have supply wire rated
at 60°C. Consult a qualified electrician before installation.
• To avoid hazards to children, account for all parts and properly dispose of all
packing materials.
• Call the Technical Support department at Con-Tech Lighting with any installation
questions: 847.559.5500.

All specifications subject to change without notice.

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