RapidLED Red Sea Max 250 Retrofit User manual

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 RapidLEDRedSeaMax250Retrofit
Contents
Foreword.......................................................................................................................................................2
Outline..........................................................................................................................................................2
HeatsinkPreparation..................................................................................................................................13
AttachingLEDstotheHeatsinks.............................................................................................................13
ThermalGrease...................................................................................................................................13
MountinganLEDtoaHeatsink...........................................................................................................13
AttachingtheBlueLEDStringstotheHeatsinks................................................................................14
AttachingtheWhiteLEDStringstotheHeatsinks..............................................................................15
HoodPreparation..........................................................................................................................................2
RemoveClearT5SplashGuard.............................................................................................................2
RemoveScrewsHoldingTwoHalvesofHoodTogether.......................................................................3
OpeningtheHood.........................................................................................................................................5
RemovingtheT5BulbSocketsandLargeBallasts........................................................................................8
RemovingT5SocketsandT5Wiring.....................................................................................................9
RemovalofBallastsandT5Sockets....................................................................................................11
DrillingtheReflectorforHeatsinkMountingHoles....................................................................................11
MountingHeatsinkstoReflector................................................................................................................17
PreparingtheLDDDriverBoard..................................................................................................................21
LDD‐H‐4BoardLayout.........................................................................................................................21
PulldownJumpers...............................................................................................................................21
InsertingLDD‐HDriversIntotheLDD‐H‐4Board........................................................................................22
InstallingStandoffs..............................................................................................................................24
InstallingtheHLGDriver.............................................................................................................................25
WiringtheLEDDrivers................................................................................................................................26
ConnectingHLGLEDOutputtoLDDInput..................................................................................................29
WiringLEDstoLDDDriversbyDrillingaHoleintheReflector...................................................................30
RoutingDimmingWires..............................................................................................................................31

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ReassemblingtheHood..............................................................................................................................36
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Foreword
Aswithanytypeoflightingretrofit,therearemanydangers,difficulties,andpitfallsthatmay
occur.TheRedSeaMax250retrofitshouldbeattemptedbypeoplefamiliarwithACpowerandwiring,
relays,electronics,LEDs,off‐LineandDC‐DCLEDDrivers,solderingLEDs,seriescircuits,andbe
comfortablewiththefactthatthisretrofitwillrequirecompletedisassemblyandremovalofsome
contentsoftheoriginalhood.Ifyouareuncomfortablewithpotentialhazards,dangers,orpitfallsthat
mayoccurinthecourseofperformingthisretrofit,youshouldnotattemptthisretrofit.Aswithall
projects,beforebeginningpleasedoublechecktoensureyouhaveallthepartsneededtocompletethe
buildandcontactusimmediatelyifanythingwasleftoutofyourorder.
Outline
Hereisageneraloutlineofassemblystepsintheorderthatworkedwellforus:
1. Removehood,removeT5bulbs,openhood,removethestockballasts,T5socketsand
bulbclips.
2. Drill4mountingholesinRSMreflectorforeachheatsink.ZiptieheatsinkstoRSM
reflector.
3. CompleteLEDwork:attachLEDstoheatsinkandthenwirethemtogether.YourLED
stringswilllikelyjumpacrosstwoheatsinks,sobeawareofthiswhenwiring.
4. InstallHLGandLDDdrivers.
5. Drillholefordimmingcontrollerwiringifnecessary.
6. CompleteWiring:WiredriverstoACpower,hookupdimmingwires,andLEDwires.
7. Testunderpower.
********ENSURETHEREISNOPOWERTOTHEDRIVERSUNTILALLWIRINGISCOMPLETE********
8. Closehoodup,re‐attachtoRSMandbaskintheshimmer.
HoodPreparation
Anyandallpowerwiresmustbeunpluggedanddisconnectedbeforebeginning.Firstwewill
separatethetwohalvesofthehoodandthenremovethelargeballastsandT5bulbsockets.
RemoveClearT5SplashGuard
First,removetheclearplasticlightcover.InstructionsforthisshouldbeinyourRSMmanual,butyou
likelywon’tneedyourmanual.Unscrewtheclearplasticcoverretainingscrewsandthenrotatethe
coveruntilitslidesoutofitsretainingclips.RemovetheT5bulbs.

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RemoveScrewsHoldingTwoHalvesofHoodTogether
Next,therearehiddenscrewsthatmustberemoved.Eachscrewiscoveredwithaplasticplugthat
mustbepoppedout.YoumustremovetheclearT5splashguardasitcoverssomescrews.
Poppingtheplugsoutismosteasilydonewithaverythinlybladedflatscrewdriver;aregularflatblade
screwdrivermightbetoothick:
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Afterremovingtheplugs,withaPhilipsscrewdriver,removeallscrewsthatwerepreviouslycoveredby
theplugs:
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Theplugsareindicatedbythearrowsinthephotosbelow.Removeallplugsandscrewsrevealedby
theirremoval.Thereare20total:

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OpeningtheHood
Thehoodiscomposedoftwomainpieces;atopandabottomwithtwoadditionalsideventpieces.To
begindisassembly,flipthehoodoversothereflectorisfacingtheground.Sinceallofthescrews
holdingthehoodtogetherhavebeenremoved,wecanseparatethetwohalves,whichhavea
somewhattightfit.Ifyouexperiencedifficulty,gobackandensureyoufoundallofthescrewplugsand
removedthescrews–wemissedoneinitiallyandalmostcrackedthehoodbytryingtoforceitopen.
Don’tforceit!Beginningwiththeouteredges,gentlypullitapartuntilyouseparatethetwopieces;
whentheouteredgesrelease,therestoftheseparationismucheasier.Donotberoughanddonot
forceitopen,itonlytakesabitofcoaxingtogetthetwomainpiecestoseparate.Workyourwayfrom
sidetoside,slidingapartthehalvesatevendistances,abitatatimeuntilthehalvesrelease.Once
separated,removetwoadditionalsideventilationpieces.
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Beginseparationhere

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Bygentlypushingupattheoutermostedges,wewereabletogetseparationandworkourwaytothe
center,eventuallyrotatingthetopcoverofthehoodawaytorevealtheinsideofthehood.
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Beginseparationhere

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Mainseparationpoint
Mainseparationpoint
TopHalfRotated90°

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RemovingtheT5BulbSocketsandLargeBallasts
Eachsideofthehoodreflectorhas5T5blubsocketsthatareclippedinwithtwowhiteplasticclips.
Simplypushtheclipoutwardanddownwardswithascrewdrivertoreleaseeachsocket.Youmayhave
toclipsomeziptiestoreleasethefanwiresbundledtotheT5socketwires(whitewires)aswewill
removetheT5socketsandleavethefans.Repeattheprocessforbothsides/all10sockets.
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PushClipsOutand
DowntoRelease
Clips(12totalperside)
ClipsforT5SocketsRemoved

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RemovingT5SocketsandT5Wiring
Next,wewillremovetheT5bulbsocketsandtheirassociatedwiringharnessesfromthehood.Todo
thiswemustdisconnectthemfromtheballasts.TodisconnecttheT5socketharnessesfromthe
ballasts,startbydisconnectingallwiresfromeachofthethreelargeballasts.Thewireterminalsonthe
ballastsarespringloaded.Simplypresstheterminaltounlockitandthenslidethewiresout.
Side2
Side1

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Pushdownwith
screwdriveron
springLoaded
terminalsand
slidewiresout
Allwiresremoved
RepeatforALLwiresonALLballasts