INSTALLATION AND MAINTENANCE MANUAL ROADWAY SIGN LIGHT Document No: 9100-127-1480-99 Rev C MAY 18, 2011 MODEL CODES Dialight Complete Fixtures RS5C4F-C (63W Cool White) see fig. 1-2 Dialight Complete Fixtures RS5C4K-C (100W Cool White) see fig. 1-2 Retrofit Cover Assemblies RS5C4F-H (63W Cool White) see fig. 3 Retrofit Cover Assemblies RS5C4K-H (100W Cool White) see fig. 3 Note: Dialight retro-fit cover assembly to fit Holophane Sign-Vue (supplied by others see page 5 for details.) Figure 1: Dialight Complete Fixture Assembly Document No: 9100-127-1480-99 Rev C Figure 1a: Dimensions: Side View of Dialight Complete Fixtures Figure 2: side View of Dialight Complete Fixture Page 2 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C Figure 3: Dialight Retro-fit Cover Assembly Figure 3a: Side View of Dialight Retro-fit Cover Only and Dialight Retro-fit Cover Assembly Mounted on SignVue Box Page 3 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C 1: Introduction This sign light is designed for illumination of roadway sign structures. It uses the latest in solid state lighting technology for long life, low maintenance, and high efficiency. The unique optical design focuses light to where it is needed, giving improved efficiency over a conventional HID luminaire. An internal power-factor-corrected switch-mode supply allows it to be used from any nominal 120V-277V, 50/60Hz AC supply without any variation in light output. This lamp is suitable for use in the following locations: • UL1598 wet locations • Indoor and outdoor non-hazardous locations Note: Save these instructions for future reference. 2: Installation (NOTE: NEITHER COMPLETE FIXTURE OR RETROFIT COVER IS RECOMMENDED FOR INVERTED OVERHEAD OR PIPE MOUNT INSTALLATIONS) Warning: To avoid the risk of fire, explosion, or electric shock, this product should be installed, inspected, and maintained by a qualified electrician only, in accordance with all applicable electrical codes. Warning: To avoid electric shock: • • Be certain electrical power is OFF before and during installation and maintenance. Luminaire must be connected to a wiring system with an equipment-grounding conductor. º For supply connections use wire rated for at least 110 C Page 4 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C The Dialight LED retro-fit cover assembly is intended to mount to Holophane Sign-Vue Series Luminaire boxes See additional box info below Holophane Sign-Vue Series Reference: Holophane drawing #fm-1751 CAD model SNVWD.dwg 11.13.08 Page 5 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C 2A: Retrofit Cover Assembly Installation Instructions: 1) Open existing cover or lid assembly and discard. 2) Remove existing bulb and reflector assembly and discard per federal requirements. When cutting the existing wire connections, be sure to maximize the length remaining with the lower unit. 3) Manufacturer recommends but does not require the removal of existing ballast, transformer, and capacitor assemblies from existing unit. 4) Place new Retrofit Cover Assembly upside down adjacent to existing lower unit. Remove existing gasket if attached to lower housing. Connect ground strap wire (provided) to existing lower housing ground location. (Hardware is provided) 5) Using Gel Filled Wire nuts connect ground pigtail (supplied) and input wires from power supply (supplied) to cut incoming power feeds on existing lower unit. 6) Connect Black wire from Power Supply to Line, Connect White wire from Power Supply to Neutral, and connect Ground pigtail (supplied) to input ground wire. 7) Place Retrofit Cover Assembly over existing lower unit insuring wires are not pinched during installation. Ensure LED light faces the sign structure. Center Retrofit Cover Assembly over existing lower unit. Secure Retrofit Cover Assembly with (24) 1/4-20 screws through existing mounting holes provided in lower housing unit. Torque hand tight. Then secure clips on rear of housing as shown. Torque 30-40 in-lbs. Finally secure front mounting bolts 30-40 in-lbs. All required mounting hardware is provided. 8) Loop safety strap around nearest rigged structure or rigged conduit entry Page 6 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C 2B: Complete fixture Assembly Installation Instructions: Type SSO (AWG 14-3) cable (normally supplied by user) is recommended for electrical connections to this luminaire. Flange Mount 1) Remove top cover assembly and place to the side. 2) Drill (4) 3/8” holes where shown in the bottom of the lower unit. Use template provided as shown below. Using these holes install housing to mounting plate (provided) and to mounting surface with (4) 5/16” bolts, nuts and lock washers. 3) Make conduit connection to lower unit. Insert the input power cable through the ¾” NPT threaded hole approximately 12”. 4) Follow steps 4 though 7 on previous page. Figure 2: View of Complete Dialight Fixture Box Assembly and Mounting Locations Complete Dialight Fixture Assembly Page 7 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C 3: Maintenance • To avoid personal injury, disconnect power to the light and allow the unit to cool down before performing maintenance. 1) Warning: No user serviceable parts inside of power supply enclosure. Risk of electric shock. Removal of the power supply cover will void the warranty, consult Dialight for authorization. a. Perform visual, mechanical and electrical inspections on a regular basis. We recommend routine checks to be made on a yearly basis. Frequency of use and environment should determine this. It is recommended to follow an Electrical Preventive Maintenance Program as described in NFPA 70B: Recommended Practice for Electrical Equipment. b. The lens should be cleaned periodically as needed to ensure continued photometric performance. Clean the lens with a damp, non-abrasive, lint-free cloth. If not sufficient, use mild soap or a liquid cleaner. Do not use an abrasive, strong alkaline or acid cleaner as damage may occur. c. Inspect the cooling fins on the luminaire to ensure that they are free of any obstructions or contamination (i.e. excessive dust build-up). Clean with a non-abrasive cloth if needed. COOLING FINS LENS Figure 3: Cooling Fins Page 8 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C 4. Specifications Nominal AC Supply Voltage 120-277VAC, 50-60Hz Maximum power consumption 63W nominal or 100W nominal dependent on model chosen Operating temperature range -40°C to +55°C -40°F to +131°F Power factor >0.9 Dimensions Cover Assembly 7.3 H x 20 W x 20.5 D (in.) ………………………………………………………...24.6 24.6 H x 50.8 W x 52.1 (cm.) Weight 25 (lbs) 11.3 (kg) Figure 4: Dimensions Page 9 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1480-99 Rev C 5. List of Required Tools Power Drill 7/16 Hex Socket GROUND PIGTAIL OUTPUT WIRES POWER SUPPLY GROUND STRAP Figure 5: Cover Assembly All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable. The accuracy or completeness thereof is not guaranteed. In accordance with Dialight Corporation “Terms and Conditions of Sale”, and since conditions of use are outside our control, the purchaser should determine the suitability of the product for his intended use and assumes all risk and liability whatsoever in connection therewith. Page 10 of 10 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com