universal douglays LED Retrofit Kit Instruction Manual

: October 27, 2023
: universal douglays

Table of Contents

SAFETY WARNINGS
UNPACKING THE KIT
SUITABLE LUMINAIRE TYPES
INSTALLATION
Documents / Resources

douglays LED Retrofit Kit
Instruction Manual

SAFETY WARNINGS

IMPORTANT SAFETY INFORMATION

DENDER
Risk of shock. Disconnect power before installation.
WARNING
Risk of fire or electric shock. LED Retrofit Kit installation requires knowledge of luminaires electrical systems. If not qualified, do not attempt installation. 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 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 installation of the LED upgrade kit. Check for enclosed wiring and components.
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

Supplied Components
(1) – (3) Universal Douglas LED Lensed Light Bars

SUITABLE LUMINAIRE TYPES

MODEL # W/O AUX	FLUORESCENT LUMINAIRE TYPES

LRKB14-30L8xxDL-U
LRKB14-40L8xxDL-U| • 1×4 Troffers: Lensed or parabolic, Type IC or Type Non- IC, 40°C max ambient, requires minimum 4“ depth. One kit per 1×4 troffer luminaire.
• 4ft vaportight, lensed, minimum 4” depth and 6.5” width, 40°C max ambient, one kit per vaportight luminaire.
LRKB24-40L8xxDL-U
LRKB24-46L8xxDL-U
LRKB24-60L8xxDL-U
LRKB24-70L8xxDL-U| • 2×4 Troffers: Lensed or parabolic, Type IC or Type Non- IC, 40°C max ambient, requires minimum 3“ depth. One kit per 2×4 troffer luminaire.
• 4ft or 8ft vaportight, lensed, minimum 4” depth and 6.5” width, 40°C max ambient, one kit per vaportight luminaire.
• 4ft or 8ft Striplight: Non-lensed, (minimum wiring compartment dimensions 2.5” depth and 4” width), 25°C max ambient, one LRKB24 per 4ft, one or two LRKB24 per 8ft striplight
LRKB34-60L8xxDL-U
LRKB34-70L8xxDL-U| • 2×4 Troffers: Lensed or parabolic, Type IC or Type Non- IC, 40°C max ambient, requires minimum 3“ depth. One kit per 2×4 troffer luminaire.

INSTALLATION

Step 1: Disconnect power to the fixture.
Step 2: For 1×4 or 2×4 luminaire installations, locate latches on the lens frame and release. Swing lens frame open and carefully allow lens to hang open as shown in Figure 1.
NOTE: For vaportights and lensed wraparound installations, remove lens and set aside.
NOTE: For stoplight 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 wiring compartment to access existing ballast and set 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 lampholder housing or cap any exposed leads. Lampholders may be removed but require removal of lampholder 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 installation of the driver. Strip wires as necessary.
Step 7: Remove ballast by unscrewing from the fixture and dispose of properly per local regulations. See Figure 6.

Step 8: Mount light bars to a flat surface adjacent to wiring compartment cover and secure with sheet metal screws. Make Sure the light bars are not mounted over holes in the luminaire surface. For single light bar kits that mount into 1×4 troffers, remove the wiring compartment cover and mount the light bar directly to the wiring compartment cover and secure with sheet metal screws (Figures 14 and 15). When using the dimming and/or auxiliary leads be sure to provide tap conductor extensions to the dimming and auxiliary leads for routing into the wiring compartment (Figures 7 and 8). Secure light bars to fixture surface with sheet metal screws (Figure 9).

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Step 9: Remove wiring compartment cover (Figure 10 —2×4 troffers). Route input leads (black and white), output leads (blue and red), dimming (violet and gray), and auxiliary leads (orange and yellow) into wiring compartment and install in accordance with the National Electrical Code (NFPA 70) and Local Codes (Figures 11, 12, 13, 16, and 17).

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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 lens and secure latches or other fastening means

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Step 1: Disconnect power to the fixture. Remove lens and set aside. Remove and dispose fluorescent lamps per local regulations.
Step 2: Remove wiring compartment cover/gear tray cover from the luminaire housing (Figures 2 and 3). Cut the input power leads to the ballast (white and black) as close as possible leaving as much length as possible to facilitate installation of the kit (Figure 4). Cut the leads to the lamp holders as close to the lamp holder socket housing as possible (Figure 5). Do not remove lamp holders. Remove and dispose the existing ballast according to local regulations.
Step 3: Place wiring compartment cover/gear tray cover back onto luminaire housing (Figure 6). Route the dimming (violet and gray) and auxiliary (orange and yellow) leads of the parent light bar (contains the driver) through an existing opening in the wiring compartment cover/gear tray cover so that the leads are completely inside the wiring compartment.

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Step 4: Mount the parent light bar to the wiring compartment/ gear tray cover and secure with the provided sheet metal screws. When installing a two light bar kit (LRKB24 series model), mount the light bars end-to-end in an 8ft vapor tight housing (Figure 9) and side by side in a 4ft vapor tight housing (Figure 10). When mounting the light bars end-to-end, tuck as much of the output leads as necessary into the light bar housing channel (Figure 11) before mounting the light bar to the wiring compartment/ gear tray cover to reduce the amount of slack (Figure 12).

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Step 5: Remove wiring compartment/gear tray cover with light bars mounted to it and route the input leads (white and black) through an existing opening in the cover (Figure 13 and 14). Route the output leads of two light bar kits (red and blue leads of LRKB24 series kits) through existing openings of the wiring compartment/gear tray cover. Connect the red and blue leads together. Connect the black and white lead to line and neutral and connect dimming control leads in accordance with the National Electrical Code (NFPA 70) and local codes.
Step 6: Place wiring compartment cover/gear tray cover with attached light bars back onto luminaire housing and secure in place. Place lens back onto the fixture housing and secure in place with the luminaire’s latches.

Step 1: Disconnect power to the fixture. Remove and dispose fluorescent lamps per local regulations.
Step 2: Remove wiring compartment cover from the luminaire housing. Cut the input power leads to the ballast (white and black) as close as possible leaving as much length as possible to facilitate installation of the kit. Cut the leads to the lamp holders as close to the lamp holder socket housing as possible. Do not remove lamp holders. Remove and dispose the existing ballast according to local regulations.
Step 3: Route the input leads (white and black) through an existing opening in the cover. Route the output leads of two light bar kits (red and blue leads of LRKB24 series kits) through existing openings of the wiring Compartment cover. Connect the red and blue leads together.
Route the dimming (violet and gray) and auxiliary (orange and yellow) leads of the parent light bar (contains the driver) through an existing opening in the wiring compartment cover/gear tray cover so that the leads are completely inside the wiring compartment.
If dimming and aux power leads are not used, keep them folded under the lightbar channel.
Step 4: Mount the parent light bar to the wiring compartment cover and secure with the provided sheet metal screws. When installing a two light bar kit (LRKB24 series model), mount the light bars end-to-end on an 8ft luminaire and side by side in a 4ft luminaire. When mounting the light bars end-to-end, tuck as much of the output leads as necessary into the light bar housing channel before mounting the light bar to the wiring compartment cover to reduce the amount of slack
Step 5: Connect the red and blue leads together. Connect the black and white lead to line and neutral and connect dimming control leads in accordance with the National Electrical Code (NFPA 70) and local codes.
Step 6: Place wiring compartment cover cover with attached light bars back onto luminaire housing and secure in place.

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Universal Lighting Technologies
Rev. 3/14/22