universal douglas LRK22-23Lyxx-U LED Retrofit Kit Instruction Manual

INSTALLATION INSTRUCTIONS
LED RETROFIT KIT
4042100 Rev

SAFETY WARNINGS

IMPORTANT SAFETY INFORMATION

DANGER
Risk of shock. Disconnect power before installation.
WARNING
Risk of fire or electric shock. LED Retrofit Kit installation requires knowledge of luminaire electrical systems. If not qualified, do not attempt installation. The product must be installed in accordance with NEC or your local electrical code. If you are not familiar with these codes and requirements, contact a qualified electrician.
WARNING
Risk of fire or electric shock. To prevent wiring damage or abrasion, do not expose wires to the edge of sheet metal or any other sharp objects.
WARNING
Risk of fire or electric shock. Check the existing wiring for damage before Installing the upgrade kit. Do not install if existing wires are damaged.
WARNING
Risk of fire or electric shock. Luminaire wiring and electrical parts may be damaged when drilling for the installation of the LED upgrade kit. Check for enclosed wiring and components.
SUITABLE FOR DRY LOCATIONS.
NOT FOR USE WITH PHASE CUT DIMMERS.
WARNING
Risk of fire or electric shock. Install this kit only in luminaires that have the construction features and dimensions shown in the photographs and/ or drawings.
Only the holes indicated in the photographs or drawings may be made or altered as a result of the kit installation. Do not leave any other holes open in a wiring enclosure or electrical component.
NOTE
THE RETROFIT KIT IS ACCEPTED AS A COMPONENT OF A LUMINAIRE WHERE THE SUITABILITY OF THE COMBINATION SHALL BE DETERMINED AUTHORITIES HAVING JURISDICTION.

UNPACKING THE KIT

Minimum Dimensions
For installation in a 2’x2′ or 21×41 luminaire, the following minimum dimensions apply:

• 3″ deep pan

• 3″ wide minimum wiring compartment

• 43″ minimum length to accommodate 4′ light bars; 22″ minimum length to accommodate 2′ light bars

• Only one kit is to be installed per luminaire
  For installation into striplights the following minimum dimensions apply:

• Minimum wiring compartment depth: 2.5″

• Minimum 3.25″ wide flat surface compartment cover width

• 43″ minimum length to accommodate 4′ light bars, 22″ minimum length to accommodate 2′ light bars
  NOTE: Consult your local authority regarding disposal or recycling procedures of removed ballast and lamps.

Supplied Components
(2) or (3) Universal Douglas LED Lensed Modules/Light Bars
(1) Universal Douglas Driver
(1) Black and White Driver Input Extension Wires
(1) Red and Blue Driver Output Extension Wires
(2)Screws supplied per 2′ Light Bar,
(3) Screws supplied per 4′ Light Bar
(2) Driver Screws (Serrated Washer)
(2) Connectors (Orange 3-Position or Yellow 4-Position)
(2) Connectors (Red, 2-Position)
(1) Relamp Label

SUITABLE LUMINAIRE TYPES

LRK22-23Lyxx-U
LRK22-30Lyxx-U
LRK22-23Lyxx-347
LRK22-30Lyxx-347| • 2×2 Troffers: Lensed or parabolic, Type IC (Insulated Ceiling) or Type Non-IC, 40°C max ambient,
requires minimum 3” depth, one LRK22 per troffer
• 2ft or 4ft Wraparound: Lensed or non-lensed, (minimum 8.5” width and 2.25” depth), 25°C max
ambient, requires minimum 3” wide wiring compartment, one LRK22 per 2ft, one or two LRK22 per 4ft
• 2ft or 4ft Striplight: Non-lensed, (requires minimum wiring compartment dimensions 2.5” depth and 4” width), 25°C max ambient, one LRK22 per 2ft, one or two LRK22 per 4ft strip light
• 2ft or 4ft Vaportight: Lensed, minimum 5” depth, and 6.75” width, 40°C max ambient, one LRK22 per 2ft vapor tight, one or two LRK22 per 4ft
• Any surface or pendant mount circular fluorescent luminaire that has a lamp compartment of overall
32 inches in diameter and 6-3/4 inches in depth from the tip of the lens to the luminaire mounting
surface, suitable for dry and damp locations, and suitable for 40°C ambient max.
LRK24-40Lyxx-U
LRK24-43Lyxx-U
LRK24-46Lyxx-U
LRK24-60Lyxx-U
LRK24-46Lyxx-347
LRK24-60Lyxx-347| • 2×4 Troffers: Lensed or parabolic, Type IC (Insulated Ceiling) or Type Non-IC, 40°C max ambient,
requires minimum 3” depth, one LRK24 per troffer
• 4ft or 8ft Wraparound: Lensed or non-lensed, (minimum 8.5” width and 2.25” depth), 25°C max
ambient, requires 3” wide minimum wiring compartment, one LRK24 per 4ft, one or two LRK24 per 8ft
• 4ft or 8ft Striplight: Non-lensed, (minimum wiring compartment dimensions 2.5” depth and 4” width),
25°C max ambient, one LRK24 per 4ft, one or two LRK24 per 8ft strip light
• 4ft or 8ft Vaportight: Lensed, minimum 5” depth, and 6.75” width, 40°C max ambient, one LRK24 per 4ft vaportight, one or two LRK24 per 8ft
• Two continuously row mounted, Type IC or Type Non-IC, 1×4 recessed troffers rated for 40°C max.
ambient with overall 4ft by 11-3/4” by 4-1/4” lamp compartment and overall 4ft by 3” by 1-1/2” wiring compartment.
LRK32-30Lyxx-U
LRK32-45Lyxx-U
LRK32-30Lyxx-347
LRK32-45Lyxx-347| • 2×2 Troffers: Lensed or parabolic, Type IC (Insulated Ceiling), 25°C max ambient, requires a minimum 3” depth, one kit per troffer
• 2×2 Troffers: Lensed or parabolic, Type Non-IC Suspended Ceiling, 40°C max ambient, requires
minimum 3” depth, one kit per troffer
• 2ft or 4ft Wraparound: Lensed or non-lensed, (minimum 8.5” width and 2.25” depth), 25°C max
ambient, one kit per wraparound (lamps mounted end-to-end for 4ft)
• 2ft or 4ft Striplight: Non-lensed, (requires minimum 2.5” depth wiring compartment), 25°C max
ambient, one kit per 2ft or 4ft striplight OR two kits per 4ft strip light
• 2ft or 4ft Vaportight: Lensed, minimum 5” depth, and 6.75” width, 25°C max ambient, one kit per
vaportight (lamps mounted end-to-end for 4ft)
• Any surface or pendant mount circular fluorescent luminaire that has a lamp compartment of overall
32 inches in diameter and 6-3/4 inches in depth from the tip of the lens to the luminaire mounting
surface, suitable for dry and damp locations, and suitable for 40°C ambient max.
LRK34-46Lyxx-U
LRK34-60Lyxx-U
LRK34-46Lyxx-347
LRK34-60Lyxx-347| • 2×4 Troffers: Lensed or parabolic, Type IC (Insulated Ceiling), 25°C max ambient, requires a minimum
3” depth, one kit per troffer
• 2×4 Troffers: Lensed or parabolic, Type Non-IC suspended ceiling, 40°C max ambient, requires
minimum 3” depth, one kit per troffer
• 4ft or 8ft Wraparound: Lensed or non-lensed, (minimum 8.5” width and 2.25” depth), 25°C max
ambient, one kit per 4ft wraparound, one or two kits per 8ft
• 4ft or 8ft Striplight: Non-lensed, (minimum wiring compartment dimensions 2.5” depth and 4” width), 25°C max ambient, one kit per 4ft, one or two kits per 8ft strip light
• 4ft or 8ft Vaportight: Lensed, minimum 5” depth and 6.75” width, 25°C max ambient, one kit per 4ft
vaportight, one or two kits per 8ft

INSTALLATION

step 1: Disconnect power to the fixture.
Step 2 : For 2×2 or 2×4 luminaire installations, locate latches on the lens frame and release. Swing lens frame open and carefully allow the lens to hang open as shown in Figure 1.

NOTE: For vapor tights and lensed wraparound installations, remove the lens and set aside.
NOTE: For striplight and non-lensed wraparound installations go to Step 3.
Step 3 : Remove existing linear fluorescent tubes as shown in Figure 2. Dispose of tubes per local regulations.

Step 4: Remove the wiring compartment to access the existing ballast and set it aside. See Figure 3.

Step 5 : Cut the leads from the ballast to the socket housing on both ends of the fixture as shown in Figure 4.

NOTE: Cut the leads at the socket housing as short as possible. Push the leads back behind the lamp holder housing or cap any exposed leads. Lampholders may be removed but require removal of lamp holder leads.
Step 6: Cut the leads from the input power to ballast. See Figure 5.
NOTE: Cut leads at the ballast leaving as much length as possible to facilitate the installation of the driver. Strip wires as necessary.

Step 7: Remove ballast by unscrewing it from the fixture and dispose of it properly per local regulations. See Figure 6.
Step 8: Locate a flat area on the fixture within the wiring compartment to mount the driver. The driver must set flush with the fixture for proper thermal management. Install the driver where possible using existing crow’s feet or mounting holes, and the provided two drill point screws with serrated heads. Ensure the driver is properly grounded. See Figure 7.

NOTE: For stoplight mounting. it is recommended to minimize exposed blue and red light bar leads to 3.
Step 9: Red finer from double-sided foam tape strips at opposite comers of the light bar. Position the light bar approximately at the centerline of existing lamp sockets and center between the sockets as shown n Figure 8. Apply pressure to temporarily affix the light bar.
NOTE: Remove any support brackets for U Bend fluorescent lamps. These are typical in some 25(2′ luminaires. For stoplight fixtures. position the lamps on the wiring compartment cover.
For circular surface or pendant mount luminaires. be careful to position the light bars so that the branch circuit wiring insulation will not be abraided or cut.
Step 10: Once positioned secure light bar to the fixture with the (6) provided self-tapping screws as shown in Figure 9. Repeat for additional light bars.

CAUTION: Foam tape is temporary for ease of installation. Do not complete retrofit installation without securing screws (3 per lamp).
Step 11: Recommended mounting pattern. See Figure 10.

Step 12: Connect red leads from both light bars to the loose red lead wire with the supplied orange 3-position connector by pushing into the open slot. Repeat for blue leads. See Figure 11.

Step 13: Connect red and blue lead wires to the comet diver contacts as indicated on the driver label. See Figure 12.

NOTE: Optional 0-10V Analog Dimming Interface

• Use Violet (+) and Gray (-) for connection to 0-10VDC.
• Capping Violet and Gray separately provides 100% light output.
• Wiring Violet and Gray together provides minimum light output.
• The dimming control connections on the LED driver are for Class 2 wiring methods only. Separate the dimming control field wiring from the branch circuit field wiring in the wiring compartment in accordance with the National Electrical Code.

Step 14 : Prepare input power leads by stripping 1/4”. Connect power lead wires to the correct driver contacts as indicated on the driver label. See
NOTE: If the existing black and white lead wires are too short to reach the new driver position, an extension can be created using the provided black and white leads and red two-position connector.

Step15: Wiring Schematics

Step 16: Replace wiring compartment cover. Dress light bar leads under the cover. Take care not to pinch red and blue leads between the cover and fixture.
Step 17: Place relamp label at a visible location in the fixture. Close or replace the lens and secure latches or other fastening means.

            www.universaldouglas.com Rev. 3/14/22

References

• Universal Douglas

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