www.osram-americas.com S90655 OSRAM ReliaSys TM D15 LED Retrofit Kit INSTALLATION GUIDE OSRAM ReliaSys TM Outdoor LED Retrofit Kit is an alternative to high-intensity discharge (HID) lamps up to 400W (MH) at pole heights up to 35 ft.* The directional light from high power LEDs and the optimized optical lens allows the delivery of light only where needed, reducing wasted light and minimizing both light trespass and upward light to reduce sky glow. The OSRAM ReliaSys TM Retrofit Kit is an environmentally preferred high efficiency lighting solution containing no mercury or lead and lowers energy consumption by up to 70% compared to HID. The long 50,000 hours life (L70) reduces maintenance and disposal costs. culus1598c Classified for shoebox applications *Results vary by fixture type PLEASE READ ALL INSTRUCTIONS BEFORE ATTEMPTING INSTALLATION TO PREVENT PERSONAL INJURY OR PRODUCT DAMAGE ONLY LICENSED ELECTRICIANS SHOULD PROVIDE ALL INSTALLATION SERVICES. FAILURE TO INSTALL THIS PRODUCT IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE (NEC), OR THE CANADIAN ELECTRICAL CODE (CSA 22.1), ALL APPLICABLE FEDERAL, STATE AND LOCAL ELECTRIC CODES AS WELL AS THE SPECIFIC UNDERWRITERS LABORATORIES (UL) SAFETY STANDARDS FOR THE INSTALLATION, LOCATION AND APPLICATION MAY CAUSE UNSAFE SITUATIONS LEADING TO SERIOUS PERSONAL INJURY, DEATH, PROPERTY DAMAGE AND/OR PRODUCT MALFUNCTION. TO AVOID ELECTRIC SHOCK OR COMPONENT DAMAGE DISCONNECT POWER BEFORE ATTEMPTING INSTALLATION OR SERVICING. INSTALLATION MUST BE STRUCTURALLY SOUND AS TO PREVENT DAMAGE OR PERSONAL INJURY DUE TO FIXTURE COLLAPSE. USE CAUTION WHEN HANDLING THIS PRODUCT DURING OR AFTER OPERATION AS IT MAY BECOME HOT AND CAUSE BURNS. DISCONNECT PRODUCT AND ALLOW COOLING PRIOR TO SERVICING. ANY ALTERATION OR MODIFICATION OF THIS PRODUCT IS EXPRESSLY FORBIDDEN AS IT MAY CAUSE SERIOUS PERSONAL INJURY, DEATH, PROPERTY DAMAGE AND/OR PRODUCT MALFUNCTION. TO PREVENT PRODUCT MALFUNCTION AND / OR ELECTRICAL SHOCK THIS PRODUCT MUST BE PROPERLY GROUNDED. DO NOT MAKE OR ALTER ANY OPEN HOLES IN AN ENCLOSURE OF WIRING OR ELECTRICAL COMPONENTS DURING KIT INSTALLATION. TO PREVENT WIRING DAMAGE OR ABRASION, DO NOT EXPOSE WIRING TO EDGES OF SHEET METAL OR OTHER SHARP OBJECTS. TO PREVENT RISK OF FIRE OR ELECTRIC SHOCK. INSTALL THIS KIT ONLY IN THE LUMINARIES THAT HAVE THE CONSTRUCTION FEATURES AND DIMENSIONS SHOWN IN THE PHOTOGRAPHS AND/OR DRAWINGS. NOTICE This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Even though this product may continue to light after the lens is cracked or broken, or after the specified lifetime has passed, it must be replaced in order to maintain appropriate light levels. Failure of fixture to provide sufficient weather protection voids warranty. This product should be operated such that the light-engine Tc point is less than 185 F (85 C) and the driver Tc point is less than 167 F (75 C). Installation requirements may vary depending on the luminaire retrofitted. Incorrect electrical polarity may damage the module. If installed in a fixture other than NRTL listed shoebox style fixture contact OSRAM customer service. 1 LED290 06/13
1. PRODUCT OVERVIEW 1.1. Products Covered Item Number Ordering Abbreviation Wattage (W) Input Voltage (VAC) Light Distribution 78942 LED140RETROFIT730T3MDX-UNV 140 120-277 Type-III Medium 78943 LED140RETROFIT741T3MDX-UNV 140 120-277 Type-III Medium 78944 LED140RETROFIT750T3MDX-UNV 140 120-277 Type-III Medium 78939 LED140RETROFIT730T5MDX-UNV 140 120-277 Type-V Medium 78940 LED140RETROFIT741T5MDX-UNV 140 120-277 Type-V Medium 78941 LED140RETROFIT750T5MDX-UNV 140 120-277 Type-V Medium 78975 LED140RETROFIT730T3MDX -HUV 140 347-480 Type-III Medium 78976 LED140RETROFIT741T3MDX -HUV 140 347-480 Type-III Medium 78977 LED140RETROFIT750T3MDX -HUV 140 347-480 Type-III Medium 78972 LED140RETROFIT730T5MDX -HUV 140 347-480 Type-V Medium 78973 LED140RETROFIT741T5MDX -HUV 140 347-480 Type-V Medium 78974 LED140RETROFIT750T5MDX -HUV 140 347-480 Type-V Medium 1.2. Next Generation LED Retrofit Kit Product Description The installation kits includes the following parts PART A (1x) LED Light Engine PART B (1x) Power Supply PART C (1x) Surge Protector (78942,78943,78944, 78939, 78940, 78941) OR PART C1 (1x) Surge Protector and PART C2 (1x) rubberized band clamp (78975,78975,78976,78976,78977,78972,78973,78974) PART D (2x) Main Bracket PART E (4x) Extension Arm PART F (28x) #8-18 ¾ long screws (24 are required) PART G (2x) Butt-splice connector PART H (2x) Mounting Flange 2
PART-A (1x) LED Light Engine Note: Light Engine Tc Point Light Engine < 85C in fixture. PART-B (1x) Power Supply 3 Note Power Supply Tc Point < 75 deg C is required. Power Supply Tc < 65 deg C is recommended for optimum performance.
There are two options for the surge protector (Part C). Option 1 is the rectangular surge protector. Option 2 consists of a cylindrical surge protector and a rubberized band clamp. Only one option is included in the kit. PART-C (OPTION 1) (1x) Surge Protector PART-C (OPTION 2) Surge Protector PART C1 (1X) PART C2 (1X) Note: Surge Protector Tc Point < 85 deg C is required. Note: Surge Protector Tc point < 85C is required. Part C1 Tc point is on the center of the top circular surface. KIT OPTIONS PART D MAIN BRACKET (2X) PART D MAIN BRACKET (2X) PART E EXTENSION ARM (4X) PART F (32X) #8-18 ¾ long screws (28 required) PART-G (2x) : Butt-Splice Connector PART H (2X) MOUNTING FLANGE Notes: Product has been properly packed to protect during transit. Unpack, inspect, and notify the distributor or shipping agent of any damage found. Installation requirements may vary depending on the luminaire retrofitted. 4
1.3. Required Tools and Hardware (Not provided) TOOLS Flat and Phillips Head Screwdriver Mechanics slip joint pliers Wire strippers Weatherproof Wire connectors HARDWARE Mounting hardware 1.4. Maintenance and Cleaning Periodic cleaning of fixture will ensure operation at maximum optical efficiency. Even though LED Retrofit Kit may continue to light after the specified lifetime has passed, it must be replaced in order to maintain appropriate light levels 2. INSTALLATION INSTRUCTIONS The D15 retrofit kit must be installed in NRTL Listed Shoebox style fixtures. The fixture must meet all of the following requirements The fixture must be constructed of metal Must incorporate a glass lens Have minimum dimensions of 15.25 x 15.25 x 6.375. WARNING! Risk of electric shock Disconnect power before servicing * Refer to fixture installation manual for fixture mounting procedures ** Please refer to www.osramamericas.com for additional installation instructions 5
FIGURE 2- D15 INSTALLED IN A SHOEBOX FIXTURE 2.1. Prepare the fixture for installation Remove the fixture cover, original ballast, ballast mounting hardware and reflector housing. 2.1.1. Remove Original Lamp System Components Note: Turn power off before attempting installation. If photocell-controlled, connect unit after external control. WARNING! Risk of burn Allow unit to cool fully before servicing Note: Failure to remove original components including ballast will void product warranty. Original Ballast Ballast Hinge Bracket Reflector Housing The light engine brackets need to mount between two flanges. If the fixture does not contain a flange then use the flanges (PART H) that have been provided. 6
2.1.2 Add Flanges (Part H) if required. Flange Mounting Screws Flanges (Part H) Flange Mounting Screws Flanges installed in a cast aluminum housing. Two screws per flange. The flanges need to be attached to the fixture with a minimum of two mounting screws per flange. The flanges are designed to be mounted to bosses in the fixture housing. Four #8-18 thread-cutting screws are provided for mounting the flanges. If the bosses are not drilled then drill them with a #28 (0.1405) drill to a depth of 1. The clearance hole in the flange will accept the #8-18 long thread-cutting screws that are provided. The diameter of the clearance hole can be increased as required. Do not use mounting screws smaller than #8. If the bosses cannot accept a screw that is ¾ long screw then the installer needs to provide the appropriate length screw. 7
2.2 Add the brackets to the D15 Light-Engine After installation the D15 bracket will rest on the fixture flange. The usable adjustment range of the bracket set is 17 to 24. FIGURE 3 1. Remove the four corner screws from the light-engine bracket (Part F). These should be discarded. 2. Install both of the fixed brackets (Part D) using two screws (Part F) per bracket. The surge suppressor (SPD) and power supply (PS) can be mounted on either the left-side or right-side fixed brackets. Both devices need to be mounted on the same bracket. 3. Install the surge suppressor (SPD) to one of the fixed brackets. The kits with a rectangular SPD (PART C) will use the four screws (Part F). The kits with a cylindrical SPD (PART C1) will use the rubberized band clamp (PART C2) and a single screw (Part F) 4. Install the PS (Part B), using four screws (Part F), to the same fixed bracket that the SPD is mounted to. FIGURE 4 shows the retrofit assembly with the rectangular SPD (PART C) FIGURE 5 shows the retrofit assembly with the cylindrical SPD and rubberized band clamp (PART C1 and PART C2) 5. Loosely install the adjustable brackets (Part E) using eight 8-18 screws (Part F) 8
FIGURE 4 For Universal Voltage (Item Numbers: 78942,78943,78944, 78939, 78940, 78941) FIGURE 5 For HUV Voltages (Item Numbers 78972,78973,78974,78975,78976,78977) 9
2.3 Mount the Light-Engine Assembly in the Fixture FIGURE 6 Some fixtures may need to be wired prior to mounting the light-engine. For these fixtures perform step 2.4 prior to 2.3. 1. Place the D15 in the fixture and adjust the brackets such that each bracket rests on the flange of the fixture. The D15 will be attached to the flange using the end holes in the adjustable brackets. 2. Mark the positions of the mounting screws and remove the D15. 3. Drill four clearance holes for the mounting screws (0.177 #16 drill) 4. Place the D15 in the fixture and adjust the brackets. 5. Fasten the adjustable brackets to the fixture using the four screws (Part F) 6. Tighten the eight screws (Part F) that hold the adjustable brackets to the D15. 2.4 Make electrical connection FOR 347/480V UNITS ONLY (NAEDS 78972-78977) these products have the power supply to light-engine connection made at the factory. Step #1 is not required for these units. 2.4.1 Make all electrical connections as shown in wiring diagram 1. These connections are performed by (1) Inserting 2 unstripped wires completely into connector (Part G) (2) Checking their position by looking through the translucent connector body, (3) While holding the tool (mechanics slip joint pliers) perpendicular to the wires make the connection by driving the cap down flush with the top edge of the connector body. IMPORTANT! DO NOT STRIP THE WIRES. These butt-splice connectors will not function properly with stripped wires. Verify that correct wire colors are connected before operation. 2.4.2 The retrofit kit must be installed in a properly grounded fixture. The original fixture will have either a ground wire or a ground terminal. There are two acceptable methods for grounding. Method one is used if the fixture has an existing ground wire connection. Method two is used if the fixture has a ground terminal. 10
Black Green White Black White Red Method 1 (Wiring Diagram 1) 2.4.3 Verify the incoming ground wire is connected to a ground location on the fixture. 2.4.4 Connect the D15 ground wire to a different ground location on the fixture using an approved grounding connector. Method 2 (Not shown) 2.4.5 Connect an approved grounding wire to a ground location on the fixture. 2.4.6 Connect the fixture ground wire, incoming ground wire and D15 ground wire using an appropriately rated wire nut. 2.4.7 If photocell-controlled wire the photocell relay in series with the line connection between the SPD and Power Supply (see wiring diagram 2). The dimming input is compatible with resistance output controls (10KOhm 100KOhm), 1-10V dimming and 10V PWM controls. For 347/480VAC input units the connection from the power supply to the dimming control needs to be made with Class I wiring. Black PWR- White PWR+ Field Installed Connections Factory Pre-wired WIRING DIAGRAM 1 Note: If the dimming function is required then the dimming wires should be connected to the control circuitry using moisture-resistant or weatherproof connectors. Otherwise, cap these wires individually with moisture-resistant or weatherproof connectors. If these wires are connected together the unit will not function. For 347/480VAC input unit the connection from the power supply to the dimming control needs to be made with Class I wiring. The ReliaSys TM D15 LED system offers 1-10V dimming. The output current of the system driver changes linearly with respect to the voltage between the DIM+ and DIM- wires. A 1V level sets the output current to 10% of the rated maximum. A 10V level sets the output current to the maximum level. If each wire is individually capped the lumen output defaults to the maximum level. The ReliaSys TM D15 LED system cannot be dimmed to less than 10%. If a 0% level (OFF) is required it is necessary to remove the input voltage to the system. This can be done mechanically or with a solid-state relay. The dimming circuit of the ReliaSys TM D15 LED system is on the secondary side of the driver which is isolated from the primary. Multiple LED140 dimming leads can be connected in parallel to a single control device. Each ReliaSys TM D15 LED driver will draw less than 1mA on the dimming circuit under all normal operating conditions. Although the maximum current drawn by the dimming input is 1mA, the current is typically 100uA. Be sure of compatibility with any relays used with the system. AC surge protector and power supply are prewired as shown in wiring diagram 1 Photocell connection wiring diagram AC Surge Photo Electric Control Black (LINE) White (NEUTRAL) Green (GND) Brown (L) Blue (N) Green (G) Power supply WIRING DIAGRAM 2 2.4 Secure fixture components 2.5 secure fixture components and restore original sealing for water tight seal 11
3. Related Documentation Related Documents LED293- OSRAM ReliaSys TM D15 LED Retrofit Kit Product Information Bulletin 4. Troubleshooting Condition Possible Reason(s) Recommended Action Green LED out on AC surge protector Surge protector unable to protect unit 1. If within warranty period, contact Sylvania sales representative for RMA. 2. If out of warranty period, contact Sylvania sales representative for information to replace surge protector. LEDs do no dim or light 1. Power supply polarity is switched 2. Power supply failed 3. LED board is damaged 4. Dimming wires not properly connected 5. Dimming control circuitry is not functioning. 1. Ensure that the red driver input wire is properly connected to the white LED output wire. Ensure that the black LED output wire is properly connected to the black driver input wire. 2. To identify failed power supply, use clamp meter (tongs) to measure output current. Replace if below rated current. Before replacing power supply, verify the green LED on surge protector is lit. 3. If within warranty period, contact OSRAM sales representative for RMA. If not within warranty period, module should be replaced as it is not user serviceable. 4. Ensure that the dimming wires are connected as described. 5. Verify the control circuitry is functioning. Difficulty experienced during mounting --- Contact OSRAM representative for recommended actions. LED290 OSRAM is a registered trademark of OSRAM GmBH. Specifications subject to change without notice For additional 12 questions or service visit www.osram-americas.com or call 1-800-LIGHTBULB