INSTALLATION AND MAINTENANCE MANUAL ROADWAY SIGN LIGHT Document No: 9100-127-1481-99 Rev A MARCH 1, 2011 MODEL CODES Dialight Retrofit Cover Assembly Dialight Retrofit Cover Assembly RS5C4F-G (70W Cool White) RS5C4K-G (100W Cool White) Note- Dialight retro-fit cover assembly to fit GE Versaflood II Signliter boxes (supplied by others) Figure 1: Dialight retro-fit cover assembly See page 3 for GE box detail Document No: 9100-127-1481-99 Rev A 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: RETROFIT COVER IS NOT 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 2 of 8 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1481-99 Rev A The Dialight LED retro-fit cover assembly is intended to mount to GE Versaflood II Signliter boxes See details below GE Versaflood II Signliter (typical box dimensions below) Page 3 of 8 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1481-99 Rev A 2: 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. Inspect existing gasket and replace with new gasket if required. Connect ground strap wire (provided) to existing fixture ground location. 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. Insure LED light faces the sign structure. Align rear hinge clips with bosses in lower fixture and place retrofit cover down onto lower assembly. 8) Loosen front, side nuts on front top side clips until they fall down below the side flange on the lower housing, then tighten nut and secure cover assembly to lower fixture 9) Loop safety strap around nearest rigged structure or rigged conduit entry Page 4 of 8 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1481-99 Rev A 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 5 of 8 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1481-99 Rev A 4. Specifications Nominal AC Supply Voltage 120-277VAC, 50-60Hz Maximum power consumption 63 W nominal or 100W nominal dependent on version 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.) ………………………………………………………...2 24.6 H x 50.8 W x 52.1 (cm.) Weight 25 (lbs) 11.3 (kg) Figure 4: Dimensions Page 6 of 8 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1481-99 Rev A 5. List of Required Tools 3/8” RATCHET 7/16 DEEP SOCKET OR 7/16” OPEN END WRENCH Figure 5: Side view Dialight Retro-fit cover assembly to GE Versaflood II Signliter box Angle between cover place and light engine assembly is 123 degrees (fixed at factory) Page 7 of 8 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com Document No: 9100-127-1481-99 Rev A GROUND PIGTAIL OUTPUT WIRES POWER SUPPLY GROUND STRAP Figure 5: Dialight Retro-fit Cover Assembly Wiring Detail 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 8 of 8 1501 Route 34 South, Farmingdale, NJ 07727 Tel: (732) 919-3119 Fax: (732) 571-5778 www.dialight.com