D4 Post Top Retrofit Kit INSTALLATION GUIDE

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1 matechllc.com D4 Post Top Retrofit Kit INSTALLATION GUIDE The D4 Post Top Retrofit Kit from MaTech Lighting Systems Designed as an easy and reliable way to convert existing fixtures Alternative to HID lamps, up to 300W MH and 200W HPS Use for pole heights up to 30 feet Eliminates mercury & lead Reduce carbon footprint & light pollution. Tested to the most demanding industry standards: o o LM-79, LM-80, In-Situ, TM-21 surge testing to UL rd edition, and DLC (pending)! WARNING 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 suffering damage, 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. To prevent early product failure, this product should be installed in operating environments with maximum mean fixture ambient operating temperature for LED Retrofit Module: 104 F (40C); maximum ambient operating temperature cannot exceed 140 F (60 C). Installation requirements may vary depending on the luminaire retrofitted. Incorrect electrical polarity may damage the module. If installed in fixture other than acorn, contact MaTech customer service to evaluate applicability to fixture. D4-RETRO

2 1. PRODUCT OVERVIEW 1.1. D4 Post Top Retrofit Specifications 30W, 40W, 60W, and 80W Versions ( LPW) designed to UL1598C True photometric performance, DLC listed 4.9 Diameter Light fits ALL globes Type 3 and Type 5 Available 4000K and 5000K CCT Available (3000K CCT Special Order) Driven by Osram Sylvania OT50W Programmable Drivers Full 0-10vdc dimming available 36 kv series surge suppression designed to UL1449 3rd edition Field adjustable height (center post telescopes locks with set screws) Electronics mount either proud or inside fixture base without disassembling unit Can be ordered with 6.5 or 8 mounting plates. Custom designs also available Options to install without center post for modular install from sides or suspended from top 5 Year replacement warranty, extended warranties available 1.2. Products Covered Part Number Watts Input LED Distribution Bracket Control Connection Voltage Color D4-RETRO30-40K-T5M-6S-STD-WL VAC 4000K Type Std None Wire Leads D4-RETRO30-50K-T5M-6S-STD-WL VAC 5000K Type Std None Wire Leads D4-RETRO40-40K-T5M-6S-STD-WL VAC 4000K Type Std None Wire Leads D4-RETRO60-50K-T5M-6S-STD-WL VAC 5000K Type Std None Wire Leads D4-RETRO60-40K-T5M-6S-STD-WL VAC 4000K Type Std None Wire Leads D4-RETRO60-50K-T5M-6S-STD-WL VAC 5000K Type Std None Wire Leads D4-RETRO80-40K-T5M-6S-STD-WL VAC 4000K Type Std None Wire Leads D4-RETRO80-50K-T5M-6S-STD-WL VAC 5000K Type Std None Wire Leads Option Encoding D4-RETROXX-30K-TXX-XX-XX-XX LED Color 3000K D4-RETROXX-XXK-T3M-XX-XX-XX Type 3 Distribution Bracket Control Connection D4-RETROXX-XXK-TXX-XX/U-XX-XX Under mount Power Supply D4-RETROXX-XXK-TXX-8N-XX-XX 8.0 No Seal D4-RETROXX-XXK-TXX-8SL-XX-XX 8.0 w/ Seal D4-RETROXX-XXK-TXX-DNLT-XX-XX Down Light Kit D4-RETROXX-XXK-TXX-XX-DIM-XX 0-10V D4-RETROXX-XXK-TXX-XX-PROG-XX D4-RETROXX-XXK-TXX-XX-XXX-TS Accessory P/N D4-SIDE-BRACKET D4-8N-BRACKET D4-8SL-BRACKET Description 5 piece adjustable side mount system 8 inch plate which replaces 6.5 inch stock plate 8 inch plate with rim seal to replace 6.5 inch plate Custom Program Terminal Strip

3 1.3. D6 LED Retrofit Kit Product Description Post Top Configuration Light Assembly Down Light Configuration with Side Brackets* 4.95 [126 mm] 3.7 [95 mm] LED Light Engine OR 24 Cable w Connector Under Mount Power Supply Height Adjustable From 18 Down To 8.25 Power Supply Assembly Height Also Available Preset upon request Surge Protector Adapter Plate 6.5 [165 mm] PART-B (3x) Wire Nuts PART-C Spare set screw PART-D Hex Key 3/32 Required Tools and Hardware (Not provided) Flat and Phillips Head Screwdriver; Pliers; Wire strippers; Wire connectors (wire Nuts) Notes: Product has been properly packed to the protect during transit. Inspect and notify the distributor or shipping agent of any damage found. For additional information visit matechllc.com, support@matechllc.com or call * Side Brackets may be used to the span the width of a fixture globe, or used to screw mount LED light engine to the hood of a light Fixture Considerations LED Light Engine Tc Point < 90C Power Supply Assembly Tc Point < 85C Remove protective cover to reach Tc point on power supplie(s)

4 2. INSTALLATION INSTRUCTIONS Refer to fixture installation manual for fixture mounting procedures Please refer to matechllc.com for additional installation instructions WARNING! Risk of electric shock Disconnect power before servicing 2.1. STEP 1: Prepare fixture for installation Turn power off before attempting installation Remove lamp, original optical components, socket, and ballast 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 optical components (reflectors) Lamp Socket Ballast POST-TOP Fixture Dome Top Fixture Globe Fixture Base Note: Minimum Total Fixture Dimensions Height 20 Min. Diameter 9 Bottom Opening 5 SHOEBOX Original Ballast Ballast Hinge Bracket Fixture Cover Reflector Housing Note: Minimum Total Fixture Dimensions Width 12 Depth 17 Height 6 Remove: Fixture cover Original ballast Reflector housing Ballast hinge bracket* *Save all mounting screws 2.2. STEP 2: Select necessary mounting accessories Review the various mounting configurations on the following pages and select the most applicable Select and install appropriate mounting accessories if needed Based on the fixture type, configure power supply assembly, brackets, and height

5 CENTER POLE MOUNTING Recommended Fixtures: Post Top Power Supply Up Height Adjustable From 18 Down To 8.25 Max Height 18 From plate to LED Board Tube Stop Screw, Remove to allow height lower than Protect cable from damage when adjusting height Power Supply Under Mounted Height Adjustable From Down To 1.5 Height is adjustable as above Remove Tube Stop Screw to allow height lower than 6.0 To move mounting plate, remove 4 screws and nuts from top (or bottom) of power supply and re-mount using same screws Note: Mounting height can be adjusted using hex key to loosen set screws, then sliding to position. Be sure to pull DC cable into position as needed when adjusting height. Tighten set screws enough to hold tube, then tighten another ½ turn. To move mounting plate, remove 4 screws and nuts from top (or bottom) of power supply and re-mount using same screws. Allow at least 1 air space around all sides of LED Light Engine from fixture. Additional air space may be needed for Tc limits. Assembled Retrofit Kit may be special ordered configured ready to drop into light fixture. These options include: o Position of mounting plate and or custom mounting plates o Height of Light Engine set to specified height o Accessory Brackets attached Contact Matech with any mounting questions or concerns.

6 SIDE BRACKET MOUNTING Recommended Fixtures: Post Top Shoebox 2.3. STEP 3: Install retrofit kit in fixture SIDE BRACKET MOUNTING For a post-top fixture Note: Screws used to mount LED module and power supply in fixture are existing screws from previous HID system.

7 CENTER POLE MOUNTING For a post-top fixture Power Supply Up Power Supply Down Note: Additional hardware maybe required to mount LED Retrofit Kit in fixture Re-use screws previously holding HID ballast to fixture to attach Retrofit Kit when possible. For Post Top fixtures, LED Light should be installed to maintain cooling clearance above heatsink, but as high as possible.. For Type-III, ensure Street Side label on light engine faces the street side For Type 3 Street Side Direction Label should point towards the street

8 2.4. STEP 4: Make electrical connections Connect each set of three wires using wire nuts as shown in the wiring diagram in Section 3 o Strip wires appropriately for the wire nuts utilized, 3/8 for those included in the kit. o The surge protector and power supply are universal voltage. The white wire may be either Neutral or Line. o Green/Yellow wire is tied to grounding conductor. If photocell-controlled or remote controlled, connect Retrofit Kit to output of the control 2.5. STEP 5: Secure fixture components Secure fixture components and restore original light fixture sealing for water tight seal 3. ELECTRICAL INSTRUCTIONS 3.1. Wiring diagram after installation AC POWER SIDE VAC LED SIDE 48 VDC. 18AWG 2 feet (Gray Jacket) 3.2. Wiring diagram after installation for 80W model AC POWER SIDE VAC LED SIDE 48 VDC. 18AWG 2 feet (Gray Jacket) Note: AC surge protector, and OPTOTRONIC power supply(s) are prewired

9 4. RELATED INFORMATION 4.1. Maintenance and Cleaning Periodic cleaning of fixture will ensure operation at maximum optical efficiency Refer to fixture installation instructions for maintenance and cleaning guidelines 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 4.2. List of applicable and related Documents D4 LED Retrofit Kit Product Information Brochure 5. Troubleshooting Condition Possible Reason(s) Recommended Action Green LED out on AC surge protector Surge protector unable to protect unit 1. If within warranty period, contact Matech sales representative for RMA. 2. If out of warranty period, contact Matech sales representative for information to replace surge protector. LEDs are dim or not lit 1. DC Cable is unplugged. 2. One or both power supplies have failed* 3. LED board is damaged *The failure of one power supply will result in dim LEDs. The failure of both power supplies will result in no light. 1. Connect the DC Cable by plugging together the two Molex connectors 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 Matech sales representative for RMA. If not within warranty period, LED Light Engine should be replaced as it is not user serviceable. Difficulty experienced during mounting --- Contact Matech representative for recommended action OR visit matechllc.com for additional reference designs. SYLVANIA is a registered trademark of OSRAM SYLVANIA INC. OPTOTRONIC is a registered trademark of OSRAM GmbH Specifications subject to change without notice