AFTER INSTALLATION DELIVER THIS MANUAL TO OWNER Holophane Company Inc. Field Service Department IMPORTANT SAFETY INSTRUCTIONS -READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO INSTALL OR MAINTAIN THIS FIXTURE. WORK MUST BE DONE BY QUALIFIED PERSONNEL. -BE CERTAIN THAT ALL ELECTRICAL POWER IS DISCONNECTED FROM THE FIXTURE BEFORE INSTALLING OR MAINTAINING THE FIXTURE. -FOLLOW LAMP MANUFACTURER'S OPERATING AND MAINTENANCE INSTRUCTIONS. Prismpack V, Prismalume V, Large Prismpack, Large Prismalume 2. INSTALLATION P.O. Box 3004 Newark, OH 43058-3004 866-759-1577 Installation and Maintenance Manual 2.1 Tools and Material Required. Table 1. Installation Tools and Materials Description Use Small blade screwdriver Set screws 5/16 Nutdriver Fasteners 3/8 Socket wrench Fasteners 1/4" Nutdriver Hanger plate set screw Torque wrench FAILURE TO FOLLOW THESE S MAY RESULT IN DEATH, INJURY OR SIGNIFICANT 2.2 Pendant Unit Installation - Figures 1 and 2. DO NOT SUSPEND THE LARGE PRISMPACK AND LARGE PRISMALUME SOLELY FROM A STANDARD OUTLET BOX. THE LUMINAIRE WEIGHT EXCEEDS THE CAPACITY OF STANDARD OUTLET BOXES. FAILURE TO PROVIDE ADDITIONAL SUPPORT MAY RESULT IN INJURY OR DEATH OR SIGNIFICANT 2.2.1 Remove hanger plate from ballast assembly. Install hanger plate on 3/4-NPT conduit. Tighten set screw. See Figure 1. PENDANT UNIT FOR PENDANT INSTALLATION Medium Units 1. INTRODUCTION Large Units GR595 NON-DISCONNECT UNIT FOR PENDANT OR THRU-WIRING INSTALLATION 1.1 Product Description. Three different mountings are covered by this manual. To identify your unit, refer to the catalog number on the nameplate label attached to the unit. 1.2 Alternate Information Sources. If additional questions arise relative to the Prismpack V or Prismalume lighting packages that this document or your supplier cannot answer, please refer them to: QUICK DISCONNECT UNIT FOR INSTALLATION TO A HOLOPHANE QDH QUICK DISCONNECT HANGER GR196, GR197A, GR195A IM-5-H
2.2.2 Install conduit bushing (installer to provide). 2.2.3 Slide ballast assembly into hanger plate. (Note: Hanger plate is indexed, housing will slide from only one direction.) 2.2.4 Make all wiring connections in accordance with approved wiring methods. 2.2.5 Install wireway cover. Tab at top of cover must be fully seated in slots at top of ballast assembly. Install and tighten the two (2) longer 10-24 screws provided to secure cover to ballast assembly. 2.2.6 Install reflector on wire yoke. Flip latches over 2.2.7 Install correct wattage and type HID lamp. Mount hanger to ceiling or girder with four (4) 1/4-20 bolts. Install conduit, conduit nuts and conduit bushing (installer to provide), tighten securely through side knockout for supply connections. - For thru-way conduit mounting, seal top entry hole with plug (if not to be used) and remove knockout for side entry. Install conduit, conduit nuts and bushings (installer to provide), tighten securely. For the Large Prismpack/Large Prismalume units, conduit connections must be capable of supporting 100 lbs. Figure 3 2.3 Non-Disconnect Unit Installation - Figure 3. 2.3.1 Loosen captive wing nut and remove ND hanger. See Figure 3. 2.3.2 Hanger Mounting Alternatives: - For pendant mount, install ND hanger on 3/4-NPT conduit. Tighten set screw inside hanger. - For ceiling mounting, seal top entry hole with plug, and remove knockout for side entry. Drill out four (4) drill spots on top of hanger with 9/32" diameter drill bit. Figure 1 GR193A 2.3.3 Hang ballast assembly from hinge pin, and make all wiring connections in accordance with approved wiring methods. 2.3.4 Swing ballast assembly up, latch J-bolt hanger, secure ballast assembly with captive wing nut. 2.3.5 Install reflector on wire yoke. Flip latches over 2.3.6 Install correct wattage and type HID lamp. Figure 2 GR190B GR192B 2.4 Quick Disconnect Unit Installation - Figure 4. NOTE The Quick Disconnect hanger may be installed only to a Holophane Quick Disconnect Hanger (shown in Figure 4). The hanger is packaged separately and installation instructions are included with it. Install the hanger following these instructions before proceeding with installation of the Quick Disconnect unit ballast assembly. For the Large Prismpack/Large Prismalume units for thru-way conduit mounting, the conduit connections must be capable of supporting 100 lbs. 2.4.1 Prepare the ballast assembly as follows: - If unit has single voltage ballast, the ballast lead connection will have been done by the factory. No further preparation is needed. Proceed to step 2.4.2.
- If unit has multi-tap ballast, strip insulation from correct voltage lead. Attach supplied black or white/black lead to stripped voltage lead with electrical wirenut. Attach flag terminal on black or black/white lead to terminal (L2) on bottom quick-disconnect half. Push excess wires into unit. 2.4.2 Hang ballast assembly hinge pin on Quick Disconnect hanger. Figure 4 QUICK DISCONNECT HANGER (PACKED SEPARATELY) GR1075, GR191A 2.4.3 Swing up ballast assembly, latch J-bolt, tighten wing nut. 2.4.4 Install reflector on wire yoke. Flip latches over 2.4.5 Install correct wattage and type HID lamp. 2.5 Installation of Options. The following factory installed options are available with the Prismpack V, Large Prismpack, Prismalume V and Large Prismalume luminaires. o EM - Standby Lighting System. o ER - Standby Lighting System for Use with 120 Volt External Power Source. o PHCB - Power Hook Cord Assembly. o PHCB-L8-480 - Power Hook Cord Assembly for 480V. 2.5.1 EM Unit Bracket Installation. The EM Unit consists of a relay assembled and wired in the ballast assembly, and a small socket for a tungsten-halogen lamp assembled to a bracket and wired to the ballast assembly. The bracket is shipped from the factory unmounted and must be mounted in the field. The steps for installation of the bracket are as follows: 2.5.1.1 Place the bracket in position over the two hex head slotted screws provided in the ballast assembly socket plate. 2.5.1.2 Tighten the screws to secure the bracket. 2.5.1.3 Refer to Sections 2.2, 2.3, or 2.4, as appropriate, for unit mounting and installation instructions. 2.5.1.4 Install correct wattage and type tungstenhalogen lamp, properly following the lamp manufacturer's instructions. 2.5.2 ER Unit Bracket Installation. The ER Unit consists of a small socket for a tungsten-halogen lamp assembled to a bracket, with the socket leads running up through the unit from the bottom to the top. The bracket is shipped from the factory unmounted and must be mounted in the field. The steps for installation of the bracket for the ER unit are identical to the installation steps for the EM Unit. For these steps, see Section 2.5.1 of this instruction manual. Connect the red leads from the tungsten-halogen lamp socket to an appropriate power supply in accordance with approved wiring practices. 2.5.3 PHCB and PHCB-L8-480 Assembly Installation. The PHCB and PHCB-L8-480 Units consist of a loop hanger, and a cord and plug for use with a Holophane Power Hook. The Power Hook is supplied separately. The installation procedure for the PHCB units are as follows: 2.5.3.1 Install the Power Hook receptacle on 3/4" conduit for either a pendant mount or a thru-way mount. Conduit connections for thru-way mounting of the Large unit must be capable of supporting 100 lbs. 2.5.3.2 Wire the Power Hook receptacle in accordance with approved wiring practices. 2.5.3.3 Hang ballast assembly onto the Power Hook using the loop hanger attached to the ballast assembly. 2.5.3.4 Plug the power cord into the receptacle. 2.5.3.5 Install reflector on wire yoke. Flip latches over 2.5.3.6 Install correct wattage and type lamp. 3. MAINTENANCE 3.1 Tools and Materials. - Screwdriver - Nutdriver - Clean, dry cloth - Torque wrench 3.2 Relamping and Cleaning of Pendant Unit and Non-Disconnect Unit. 3.2.1 De-energize the luminaire. 3.2.2 Wipe off the reflector to remove dirt or debris. 3.2.3 Remove the lamp. 3.2.4 Securely install a new lamp of proper type and wattage.
3.2.5 Re-energize the luminaire. 3.3 Relamping and Cleaning of Quick Disconnect Unit. 3.3.1 Loosen captive J-bolt wing nut, unlatch wing nut, and swing ballast assembly down. 3.3.2 Wipe off the reflector to remove dirt or debris. 3.3.3 Remove the lamp. 3.3.4 Securely install a new lamp of proper type and wattage. 3.3.5 Swing ballast assembly up, latch J-bolt, and tighten wing nut. 3.4 Removal of Pendant Unit. 3.4.1 De-energize the luminaire. 3.4.2 Remove the lamp. 3.4.3 Detach reflector from wire yoke if necessary. 3.4.4 Remove wireway cover by removing two screws that secure it to the hanger plate. 3.4.5 Disconnect supply wires and ground wire. 3.4.6 Slide ballast assembly off hanger plate. 3.5 Removal of Non-Disconnect Unit. 3.5.1 De-energize the luminaire. 3.5.2 Remove the lamp. 3.5.3 Detach reflector from wire yoke if necessary. 3.5.4 Loosen captive J-bolt wing nut and unlatch wing nut. 3.5.5 Swing ballast assembly down. 3.5.6 Disconnect supply wires and ground wires. 3.5.7 Remove ballast assembly from hanger. 3.6 Removal of Quick Disconnection Unit. 3.6.1 Loosen captive J-bolt wing nut and unlatch wing nut. 3.6.2 Swing ballast assembly down. 3.6.3 Remove the lamp. 3.6.4 Detach reflector from wire yoke if necessary. 3.6.5 Remove ballast assembly from hanger. 3.7 Electrical Component Replacement. Electrical components located inside the ballast assembly can be replaced as follows: REPLACEMENT OF COMPONENTS LOCATED INSIDE THE BALLAST ASSEMBLY MUST BE DONE ONLY WITH THE FIXTURE REMOVED FROM ITS INSTALLED POSITION. THE BALLAST ASSEMBLY MUST BE PLACED ON A HORIZONTAL WORK SURFACE BEFORE ATTEMPTING TO REMOVE EITHER OF THE TWO LARGE CLOSURE SCREWS IN THE BOTTOM OF THE HOUSING. FAILURE TO DO SO MAY RESULT IN INJURY OR DEATH OR SERIOUS PROPERTY DAMAGE FROM FALLING OBJECTS. 3.7.1 De-energize the luminaire and remove the unit following Sections 3.4, 3.5, or 3.6 as appropriate. 3.7.2 Place unit on horizontal work surface so that socket area is accessible. 3.7.3 Remove two hex slotted washer head screws securing wire yoke and socket plate. Removal of these screws also loosens ballast mounting strap for medium unit 3.7.4 Remove wire yoke and socket plate to access components. Two additional washer head screws must be removed in Large Unit to remove a separate component mounting strap. 3.7.5 Tag electrical leads for use when installing the new components. Break electrical connections. 3.7.6 Remove the attaching hardware if applicable and retain for re-use. 3.7.7 Remove the electrical component. Check the interior of the housing for evidence of damage or potentially hazardous conditions. 3.7.8 Place the new component into position. Install the attaching hardware if applicable. Tighten securely. 3.7.9 Make electrical connections in accordance with wire tags and approved wiring practices. 3.7.10 Reinstall component mounting strap in Large unit. 3.7.11 Reinstall socket plate and wire yoke with two hex slotted washer head screws and torque them to 55-65 in.-lb. Be sure screws are fully seated and are not cross threaded. FAILURE TO INSTALL THE PROPER SCREWS, OR FAILING TO FOLLOW THE PROPER PROCEDURES MAY RESULT IN DEATH OR SERIOUS PROPERTY DAMAGE. 3.7.12 Check the exterior of the housing for evidence of damage or potentially hazardous conditions.
REPLACE ANY DAMAGED COMPONENTS (CONTACT HOLOPHANE FIELD SERVICE DEPARTMENT). FAILURE TO DO SO MAY RESULT IN SIGNIFICANT 3.7.13 Refer to Sections 2.2, 2.3, 2.4 and 2.5 of this document for reinstallation of the respective ballast assembly. 3.7.14 Once the unit is reinstalled, re-energize the lamp and check for proper operation and area illumination. 3.8 Maintenance of Options. BE CERTAIN THAT ALL ELECTRICAL POWER IS DISCONNECTED FROM THE FIXTURE BEFORE INSTALLING OR MAINTAINING THE FIXTURE. FAILURE TO DO SO MAY RESULT IN INJURY OR DEATH. 3.8.1 EM/ER Unit. Removal of the EM/ER Units for maintenance is accomplished by following steps outlined in Sections 3.4, 3.5, and 3.6. Electrical components located inside the ballast assembly can be replaced by following the steps outlined in Section 3.7. 3.8.2 PHCB and PHCB-L8-480 Assembly. 3.8.2.1 Removal of the PHCB Units is as follows: Deenergize the luminaire. Remove the lamp and reflector if necessary. Unplug power cord from the power hook receptacle and remove ballast assembly from the power hook. 3.8.2.2 Electrical components located inside the ballast assembly can be replaced by following the steps outlined in Section 3.5 of this instruction manual. The PHCB Units may be reinstalled by referring to Section 2.5.3 of this instruction manual. 3.9 HALT Option 3.9.1 A bright green label affixed to the bottom of the ballast housing indicates that the luminaire is supplied with Holophane Automatic Lamp Timeout System. HALT System extinguishes the HID lamp for a minimum of 15 minutes for every 100 to 300 hours of operation thus complying with lamp company recommendations for Metal Halide lamps. To minimize the potential that adjacent luminaires are extinguished simultaneously, the HALT System cycles each luminaire off at random time periods between 100 and 300 hours. 4 Limited Warranty and Limitation of Liability The Holophane limited warranty and limitation of liability is published in the "Terms and Conditions" section of the current Holophane buyer's guide, and is available from your local Holophane sales representative. Acuity Lighting Group, Inc. 214 Oakwood Ave., Newark, OH 43055 IM-5-G 5/02 2002 Acuity Brands Inc. Visit our web site at www.holophane.com