OSRAM ReliaSysTM 145W LED Retrofit Kit

OSRAM ReliaSysTM 145W LED Retrofit Kit
www.osram-americas.com
S90655
OSRAM ReliaSysTM
D15 LED Retrofit Kit
INSTALLATION GUIDE
OSRAM ReliaSysTM 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
ReliaSysTM 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
3Note

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 2)
Surge Protector
PART-C (OPTION 1) (1x)
Surge Protector
PART C1 (1X)
Note:
Surge Protector Tc Point < 85 deg C is required.
PART C2 (1X)
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-G (2x) : Butt-Splice Connector
PART E – EXTENSION ARM (4X)
PART F – (32X)
#8-18 ¾” long screws (28 required)
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
10
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.
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 ReliaSysTM 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 ReliaSysTM 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 ReliaSysTM 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 ReliaSysTM 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
Red
Black
White
Green
Black
Black (LINE)
White
Photo Electric
Control
AC Surge
Brown (L)
White
(NEUTRAL)
Green (GND)
WIRING DIAGRAM 2
2.4 Secure fixture components
2.5 secure fixture components and restore original sealing for water tight seal
11
Blue (N)
Green (G)
Power supply
3. Related Documentation
Related Documents

LED293- OSRAM ReliaSysTM D15 LED Retrofit Kit Product Information Bulletin
4. Troubleshooting
Condition
Green LED out on AC surge
protector
LEDs do no dim or light
Difficulty experienced during
mounting
Possible Reason(s)
Surge protector unable to
protect unit
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.
---
Recommended Action
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.
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.
Contact OSRAM representative for
recommended actions.
LED290
OSRAM is a registered trademark of OSRAM GmBH.
Specifications subject to change without notice
12
For additional
questions or service visit www.osram-americas.com or call 1-800-LIGHTBULB
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