Sylvania D6 User manual

D6 Area Light LED Retrofit Kit
INSTALLATION GUIDE
Above image of 55W model.
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 the lens is cracked or broken, 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 ambient operating
temperature for LED Retrofit Module: 104°F (40C); 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 or shoebox, contact UL customer service department at [phone] to certify retrofitted fixture.
The D6 Area Light LED Retrofit Kit from SYLVANIA is an
alternative to high-intensity discharge (HID) lamps up to 175W
at pole heights up to 30 feet. The directional light distribution of
high power LEDs allows the delivery of light only where
needed, reducing wasted light and minimizing light trespass
and upward emissions. The D6 is an environmentally friendly
lighting solution as it contains no mercury or lead. It is an
excellent solution for communities that wish to convert their
existing lighting systems as it offers substantial energy and
maintenance cost savings as well as minimizes waste in
landfills.
RETRO0018 07/10
www.sylvania.com

1. PRODUCT OVERVIEW
1.1. Products Covered
Item
Number
Ordering
Abbreviation
Wattage (W)
Input Voltage
(VAC)
Light
Distribution
78628
LED55RETROFIT/750/T5M/D6
55
120-277
Type-V Medium
78629
LED55RETROFIT/756/T5S/D6
55
120-277
Type-V Short
78630
LED55RETROFIT/750/T3M/D6
55
120-277
Type-III Medium
78631
LED55RETROFIT/756/T3S/D6
55
120-277
Type-III Short
78645
LED55RETROFIT/741/T5M/D6
55
120-277
Type-V Medium
78646
LED35RETROFIT/750/T5M/D6
35
120-277
Type-V Medium
78647
LED35RETROFIT/741/T5M/D6
35
120-277
Type-V Medium
1.2. D6 LED Retrofit Kit Product Description
Notes:
Product has been properly packed to protect during transit. Unpack, inspect, and notify the distributor or shipping agent of any damage found.
For additional information visit www.sylvania.com or call 1-800-LIGHTBULB (1-800-544-4828)
* PART-B (Power Supply Assembly) displayed is for the 55W model. 35W model contains only one power supply.
* PART-C (Top Bracket) may be used to mount unit from top, if desired. Reference designs can be found at mySylvania.com.
PART-C (1x)*
Top Bracket
PART-E (8x)
#8 Screws (extra 4x
supplied)
PART-F (4x)
Side Bracket
5.8”
[148 mm]
1.1”
[29mm]
PART-G (2x)
3M Connectors
PART-H (1x)
Mounting Pole
12”
[165 mm]
½” NPT
½” NPSM 4” long
PART-D (1x)
½” Locknut
PART-B: 35W Model (1x)
Power Supply Assembly
6.2”
[157mm]
Insulation Block
Surge Protector
Adapter Disk
6.5”
[165 mm]
Power Supply (s)
PART-B: 55W Model (1x)
Power Supply Assembly
6.5”
[165 mm]
6.2”
[157mm]
Required Tools and Hardware (Not
provided)
Flat and Phillips Head Screwdriver;
Pliers; Wire strippers; Wire connectors
(wire Nuts)
PART-A (1x)
LED Light Engine
6.8”
[172 mm]
3.7”
[95 mm]

1.3. Fixture Considerations
Note:
Please contact your Sylvania representative for reference design of the mounting hardware.
1.4. 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
LED Light Engine
Tc Point < 75C
Power Supply Assembly
Tc Point < 80C
35W Models
55W Models

2. INSTALLATION INSTRUCTIONS
* Refer to fixture installation manual for fixture mounting procedures
** Please refer to www.Sylvania.com for additional installation instructions
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
Note: Minimum total fixture dimensions
Height
Width at Largest Diameter
Bottom Opening
20”
9”
7.5”
Note: Minimum total fixture dimensions
Width
Depth
Height
12”
17 1/8”
6”
SHOEBOX
Original Ballast
Reflector Housing
Ballast Hinge
Bracket
Fixture Cover
Remove:
Fixture cover
Original ballast
Reflector housing
Ballast hinge bracket*
*Save all mounting screws
Original optical
components
(reflectors)
Fixture Dome Top
Ballast
Socket
Lamp
Fixture Base
Fixture Globe
WARNING
!Risk of electric shock
Disconnect power before servicing
WARNING
!Risk of burn
Allow unit to cool fully before servicing
POST-TOP
Note: Failure to remove original components
including ballast will void product warranty.

2.2. STEP 2: Select necessary mounting accessories
Depending on the fixture type, select and install appropriate mounting accessories
SIDE BRACKET MOUNTING
Recommended Fixtures:
Post Top
Shoebox
E (4x)
F
(4x)
A
B
*Note: 55W model power supply shown in image above.

A
D
DC Pigtail
Insulation
Block
Power Supply Down
A
B
D
H
Power Supply Up
DC Pigtail
B
H
CENTER POLE MOUNTING
Recommended Fixtures:
Post Top
*Note: 55W model power supply shown in images above.

2.3. STEP 3: Install retrofit kit in fixture
SIDE BRACKET MOUNTING
For a post-top fixture
A
F
B
Note: Screws used to mount LED module and power supply
in fixture are existing screws from previous HID system.
Note:
Mounting height can be regulated using locking nut.
To attach mounting disk, remove insulation block from top of power supply and re-mount using same screws.
Route DC pigtail down PART-H (mounting pole).
Allow at least 1” space around PART-A from fixture.
PART-H may be altered per specific fixture requirements by the following guidelines
oCutting and rethreading ½” NPT side of PART-H: Minimum overall conduit length not to be less than 5 inches
oExtending using standard ½” metal electrical conduit fittings: Maximum overall conduit length not to exceed 30
inches
oBending of PART-H: Bending should not cause PART-A to be within 1” of fixture
Product ships configured with power supply up; insulation block must be mounted on disk when used in configuration with
power supply down.

Street Side Direction
Label should point
towards the street
CENTER POLE MOUNTING
Post-Top
Power Supply Down
Post-Top
Power Supply Up
Note:
Additional hardware is required to mount LED Retrofit Kit in fixture
Re-use screws previously holding HID ballast to fixture to attach Retrofit Kit.
For Post Top fixtures, PART-A should be installed as high as possible maintaining the minimum distance shown in Section 1.3
For Type-III, ensure “Street Side” labels on side of heat-sink and optics face street side
55 W model power supply shown in images above



2.4. STEP 4: Make electrical connections
Connect each set of three wires using connectors (G) as shown in the wiring diagram in Section 3
oFully insert three unstripped wires into connector (G) and make connection by pressing cap into unit
oVerify that correct wire colors are connected before operation
If photocell-controlled, connect unit after external control
2.5. STEP 5: Secure fixture components
Secure fixture components and restore original sealing for water tight seal
3. ELECTRICAL INSTRUCTIONS
3.1. Wiring diagram after installation for 55W model
White (+)
Black (-)
Purple (+)
Purple (+)
White (N)
Black (-)
Black (-)
Black (L)
Green (GND)
G (2x)
Should be
connected by
installer using
PART-G
Red (+)
Black (-)
Black (L)
White (N)
Power Supply
OT40/UNIV/1110E
AC Surge
Protector
Green (GND)
Power Supply
OT40/UNIV/1110E
LED
Board
POWER SUPPLY ASSEMBLY LED LIGHT ENGINE
Purple (+)
Black (-)
Purple (+)
Black (-) Two 3M
connectors
provided
AC POWER SIDE
120-277 VAC
(White Jacket) 16AWG –1 feet
LED SIDE
18-36 VDC.
(Blue Jacket) 20AWG –4 feet
White (+)
Before connections
After connections
55W Model
35W Model

3.2. Wiring diagram after installation for 35W model
4. RELATED INFORMATION
4.1. List of applicable and related Documents
Document RETRO017 –D6 LED Retrofit Kit Product Information Brochure
White (+)
Black (-)
Purple (+)
White (N)
Black (-)
Black (L)
Green (GND)
G (2x)
Red
(+)
Black
(
-
)
Black
(
L
)
White
(
N
)
AC Surge
Protector
Green
(
GND
)
Power Supply
OT
40
/
UNIV
/
1400
E
LED
Board
POWER SUPPLY ASSEMBLY
LED LIGHT ENGINE
Purple
(+)
Black
(
-
)
)
Two
3
M
connectors
provided
AC POWER SIDE
120-277 VAC
(White Jacket) 16AWG –1 feet
LED SIDE
18-36 VDC.
(Blue Jacket) 20AWG –4 feet
White (+)
Should be
connected by
installer using
PART-G
Note:
AC surge protector, and OPTOTRONIC® power supply(s) are prewired in PART-B

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
Sylvania sales representative for
RMA.
2. If out of warranty period, contact
Sylvania sales representative for
information to replace surge protector.
LEDs are dim or not lit
1. Power supply polarity is
switched
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. Ensure white wire is attached to purple
output wires of power supplies.
Ensure black wire is attached to black
output wires of power supplies.
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
Sylvania sales representative for
RMA. If not within warranty period,
module should be replaced as it is not
user serviceable.
Difficulty experienced
during mounting
---
Contact Sylvania representative for
recommended action.
To order replacement retrofit
kits please contact
OSRAM SYLVANIA
National Customer
Service and Sales Center
18725 N. Union Street
Westfield, IN 46074 USA
Industrial Commercial
Phone: [phone]
Fax: [phone]
National Accounts
Phone: [phone]
Fax: [phone]
OEM/Special Markets
Phone: [phone]
Fax: [phone]
Display/Optic
Phone: [phone]
Fax: [phone]
In Canada
OSRAM SYLVANIA LTD
Headquarters
2001 Drew Road
Mississauga, ON L5S 1S4
Industrial Commercial
Phone: [phone]
Fax: [phone]
Special Markets
Phone: [phone]
Fax: [phone]
Visit our website:
www.sylvania.com
SYLVANIA is a registered trademark of OSRAM SYLVANIA INC.
OPTOTRONIC is a registered trademark of OSRAM GmbH
Specifications subject to change without notice