380VDC 6-Lamp Ballast Retrofit Installation and User`s Manual
Contents
1. Charge Dumm H0 din ami Chipul io Site PDC mA Ligii Qala iip io Ai biune Mian Factor 0 Tl Operas wih oe PASTE FTE Peo FRAP waw dibalas com all a a es Figs ay ee set pepe sa na Installation and User s Manual 380VDC SIX LAMP BALLAST MODEL NB380 T832 06 ISBL Rev 040114 Please contact Customer Support at 1 800 24VOLTS for further information eee a iVvicrgqe ALLIANCE t GIS TERED LISTED Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world E r gt 380VDG 6 Lamp Ballast Retrofit Kit nstallationrand Users Manual 6 642 395 and Oher ai Charge Coman i maa Peer i China Uo ie 27 0 Lumen TABLE OF CONTENTS ABOUT NEXTEK POWER SYSTEMS 3 INTRODUCTION OVERVIEW 4 1 0 SAFETY 5 2 0 STANDARDS amp REQUIREMENTS 6 3 0 REGULATORY INFORMATION 7 4 0 TRAINING 7 5 0 FEATURES AND SPECIFICATIONS 8 6 0 GENERAL REQUIREMENTS 9 7 0 INSTALLATION PROCEDURE 11 8 0 NOTES 16 For more information Nextek Power Systems Tel 313 887 1321 www nextekpower com Detroit Michigan 48202 Fax 313 887 9483 info nextekpower com 2 Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world Rev 040114 C ll gt Fi 6 680 595 and Oher 380VDG 6 Lamp Ballast Retrofit Kit installation and User s Manual Tee H Maui le 3 maa Peer i Chi2. 7 1 1 gt NOTE If an AC ballast has been previously installed in the location refer to the Nextek Ballast Retrofit Kit Installation and User Manual for ballast removal procedures The manual is available for download at www nextekpower com WARNING Shock Hazard At the supply panel disconnect power to the luminaire s WARNING Risk of fire or electric shock Luminaire wiring and A cectica parts may be damaged when drilling for installation of unit Check for enclosed wiring and components 7 1 3 CAUTION Gain access to the ballast wiring enclosure and remove A a line voltage wiring between existing ballast and the nearest junction box including any ground wires and armored cable If the luminaire was powered by line voltage from an adjacent luminaire remove any line voltage wiring between the luminaires Cap off any exposed live leads with included wire nuts 7 1 4 Cut control wires going to the line voltage ballast if present 7 1 5 Cut the lampholder wires at the ballast and strip the cut ends to wire nut specifications 7 1 6 Remove the old line voltage ballast Figure 7 1 4 Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world 11 Rev 040114 C s p bo 380 VDC 6 Lamp Ballast Retrofit Kit nstallationand Users Manual aa 0 395 ened Ober F g a BG 335 am naa Mam Meee ink Coin Up be 21 00 Lumens 7 0 I
3. Purple Black striped SW2 Gray SW1 amp SWe Orange SW1 Purple and Gray Orange Black striped SW2 SW1 amp SW2 Simple Switch Wiring Table gt NOTE The Orange and Orange Black Striped wires are unused cap off with wire nuts Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world 13 Rev 040114 380VDG 6 Lamp Ballast Retrofit Kit Mnstallationand UsersiManual 7 0 INSTALLATION PROCEDURE Switch Type Pwrin Pwrin Switch s First Contact Switch s Second Contact Normally Purple SW1 puleacesrpea swa Sry SW1 amp SH Normally Brown Gra Orange SW1 Purple and Gray Closed y Orange Black striped SW2 SW1 amp SW2 Smart Switch Wiring Table NOTE The connection to Gray is not necessary if the Switch is internally grounded 7 1 14 The Brown and Gray wires are for the Auxiliary 24VDC supply The supply is designed for 24VDC low power devices like smart switches or the Nextek Power Systems Emergency Ballast The polarity for the 24VDC supply is the brown lead is 24VDC and the gray lead is 24VDC If the Auxiliary supply is not required then cap off the brown and gray leads individually 7 1 15 Connect Nextek 380 Volt DC ballast input leads black wire 380VDC and white stripped red wire 380VDC to a suitably rated 90 C conduit enclosed 380VDC bus line inside the luminaire with no exposed wiring wire must be in condu
4. 24 0 men 0 8 ind 327 0 mm 13 75 inl fhe mim 74 2 int 5 4 Kit contents 1 Ballast 2 These instructions 3 Wire nuts 18 for six lamp ballast conversion 4 Cable ties 6 5 Labels to be affixed to exterior of luminaire o Hommia i a a 7 Ea E Luminaire Conversion Retrofit This luminaire contains a 380V DC input ballast Nextek Power Systems 461 Burroughs St Detroit MI 48202 www nextekpower com Use only with 380VDC Class 1 Power Unit Do not connect to line voltage Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world Rev 040114 E sie baa 380VDC 6 Lamp Ballast Retrofit Kit Installation and User s Manuals pints a Cio P eee Dhare CERN 5 590 395 and ih Jisa re eee i Chin Up ie 2 0 Lumen 6 0 GENERAL REQUIREMENTS 6 1 Every work environment should provide a safe place for every employee which includes protecting the employee from electrical hazards such as fault currents to ground 6 2 When an electrical ground fault occurs the current flows through the path having minimum impedance to ground It is imperative that an employee does not inadvertently become the conductor of the current 6 3 Two approved methods of protecting the worker from a ground fault in addition to other requirements for equipment grounding conductors are 6 3 1 Use of ground fault circuit interrupters GFCI 6 3 2 An ass
5. either the exclusive property of Nextek Power Systems Inc or other companies Copyright 2013 2014 by Nextek Power Systems Inc in the United States and other countries throughout the world Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world 3 Rev 040114 CC a 380VDG 6 Lamp Ballast Retrofit Kit Installation and User s Manual i ol er F 5 BEHI PAS 0 D ea a i 1 edt Paii Up tm ATOL LENENG INTRODUCTION Nextek Ballasts e Nextek s 380VDC Ballast Retrofit Kit converts existing luminaires from AC power to high efficiency bus voltage Direct Current DC power by simply replacing the ballasts e Convert luminaires without replacing bulbs or system wiring Nextek ballasts are sized to use pre existing mounting holes and hardware too e The simple procedure takes only minutes to complete e Nextek s Maximum Power Point Tracking Controller is recommended for greatest system efficiency and control HIGH VOLTAGE DIRECT CURRENT INPUT FROM PV PANEL HVDC GRID OR OTHER DC POWER GENERATOR BATTERY By oan CONVERTER EMERGE STANDARDIZED LOW VOLTAGE SUSPENDED CEILING GRID AC GRID POWER INPUT NEXTEK 380VDC 16 LAMP BALLASTS a FLUORESCENT LUMINAIRES _ Nextek ballasts in a Direct Current microgrid power system 4 Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in
6. other countries throughout the world Rev 040114 E sie daai 380VDG 6 Lamp Ballast Retrofit Kit limstallatiomand UsersiManual ki sity 05 and ihar F Pe CEREN SeN 6 635 La eo eee inkl Cato Up ie 2100 Lue 1 0 SAFETY 1 1 SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for the Nextek Ballast Retrofit Kit The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially dangerous condition Use extreme caution when performing this task CAUTION Indicates a critical procedure for safe and proper operation of the controller NOTE Indicates a procedure or function that is important for the safe and proper operation of the controller 1 2 Before using the Ballast Retrofit Kit read all instructions and cautionary markings 1 3 Electrical hazards are probably the most common hazards throughout the industry Virtually all workplaces have electrical installations and use electricity 1 4 Itis very important that all industry employees be familiar with electrical hazards and know how to protect themselves when working on near or with electricity In most cases industry electrical and electronic equipment is designed for both maximum safety and efficie
7. 33 A 7 ENIA ARA www nextekpower com info nextekpower com
8. NSTALLATION PROCEDURE 7 1 7 Mount the new Nextek 380VDC ballast using existing studs or screws If necessary secure ballasts using appropriately sized sheet metal screws If no existing hole or stud exists at the correct mounting location use a self tapping sheet metal screw 7 1 8 For pre existing mounting studs or holes 7 1 8 1 Carefully align the ballast slot to one mounting hole or stud and insert a sheet metal screw with a star washer The washer is for enclosure to fixture grounding purposes 7 1 8 2 Do not tighten the screw completely Leave a 1 4 6 mm gap between the mounting surface and screw head 7 1 8 3 Carefully align the ballast slot to one mounting hole or stud and insert a sheet metal screw 7 1 8 4 When the ballast is properly positioned tighten both 2 screws 7 1 8 5 Proceed to step 7 1 10 7 1 9 Fora surface with no pre existing mounting studs or holes 7 1 9 1 Place a mark on the mounting surface for one of the mounting holes in accordance with the luminaire manufacturer s instructions or drawings 7 1 9 2 Use a self tapping sheet metal screw to insert the first screw at the mark 7 1 9 3 Do not tighten the screw completely Leave a 1 4 6 mm gap between the mounting surface and screw head 7 1 9 4 Mark the second mounting hole location for the ballast 7 1 9 5 Carefully align the ballast slot to the second mounting hole and insert a sheet metal screw 7 1 9 6 When the ballast is prope
9. accepted as a component of a fluorescent luminaire where the suitability of the combination shall be determined by CSA or authorities having jurisdiction Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world 9 Rev 040114 380VDC 6 Lamp Ballast Retrofit Kit nstallationand Users Manual L and Chae F Bait tet mee m EEO J and ee a moa aes Lindl Cann Up ia 21000 Laman E l 6 0 GENERAL REQUIREMENTS 6 4 9 gt NOTE Inspect wiring and components for damage when drilling for installation of retrofit assembly hardware 6 5 Recommended Tools 6 5 1 This installation may require the following depending on the installation of specific ballasts and existing wiring 2 and 0 Phillips screwdrivers Slotted screwdriver Wire strippers Wire cutters Pliers 10 Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world Rev 040114 CN pa 380VDG 6 Lamp Ballast Retrofit Kit nstallation and User s Manuals T md hacer rete iiaia 6 600 85 im nas Mam Meee i Cain Up be 21 0RW0 Lumens 7 0 INSTALLATION PROCEDURE 7 1 380VDC 6 LAMP BALLAST MODELS 380VDC 6 LAMP BALLAST WIRING DIAGRAM RED 380VDC 24VDC BROWN ORANGE _ SW2 1 ELECTRONIC BALLAST SW 1 1 ORANGE PURPLE SW2 2 SW1 2 PURPLE 7 j L owes L owe BLUE lt N MOT1SA awe J
10. authority to operate the equipment Note This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 18 of the FCC rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communication However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment on and off the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help 4 0 INSTALLATION QUALIFICATIONS 4 1 Installation work and electrical wiring of permanently connected power units must be performed only by qualified service personnel in accordance with all applicable codes and standards including fire rated construction Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the Unite
11. cated in the photographs and or drawings may be made or altered as a result of kit installation Do not leave any other open holes in an enclosure of wiring or electrical components 1 6 7 A listed Class 1 380VDC output supply such as a 380VDC bus line may be used as a power source for the Nextek 380VDC ballast 1 6 8 These Nextek 380VDC ballasts are intended for use only with non IC luminaires not intended for Insulation Contact including any ground wires between the line voltage ballast and the 1 7 SHOCK CAREFULLY FOLLOW THESE INSTRUCTIONS 1 6 9 Before wiring 380VDC supply to ballasts remove any old AC wiring nearest junction box DANGER TO REDUCE THE RISK OF FIRE OR ELECTRIC 1 7 1 Do not disassemble or attempt to repair the ballasts There are no user serviceable parts inside Nextek ballasts 1 7 2 Install external fuses breakers as required 1 7 3 Disconnect power to the luminaire before installing the ballasts removing old ballasts or wiring or otherwise working with the unit 1 8 INSTALLATION SAFETY PRECAUTIONS 1 8 1 Mount the Ballast Retrofit Kit indoors only Prevent exposure to the elements 1 8 2 Power connections must remain tight to avoid excessive heating from a loose connection 1 8 3 Use properly sized conductors and circuit interrupters 1 8 4 The Nextek Ballast Retrofit Kit is to be connected to DC circuits only 6 Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the Unit
12. d States and in other countries throughout the world 7 Rev 040114 380VDG 6 Lamp Ballast Retrofit Kit 5 0 C ll D a 6 6401 395 and Cher Pate BALLAST FEATURES AND SPECIFICATIONS 5 1 Features e Tri stage dimming that allows for 0 33 66 and 100 of the lamps to be lit e Simple Mechanical Smart Switch configurable with NO NC e gt 97 efficient e Class 2 safe 24VDC 250mA out for powering ballast accessories e g Smart Switches and emergency backup ballasts 5 2 Technical Specifications Installation and User s Manual Sarii Share CLA maa Peer i China Uo ie 27 0 Lumen Auxiliary Output supply of 24VDC 250mA to power smart switches Simple Mechanical Smart Switch configurable Works at 10 65 C ambient perfect for Highbay applications Low cost 6 lamp class ballast Type 1 Class P Sound rated A UL 935 UL E242233 CUL listed CSA 22 2 Operating Voltage 380 VDC nominal Dimming Tri level 10 Dimensions W 1 7 H 1 2 L 14 2 Operating Current 0 60 Amp 380V DC 44mm x 31mm x 362mm Operating Weight 1 5 Ibs Temperature 10 C 65 C Construction Steel Maximum Ballast Operated With F32T8 F32TS8ES Factor 1 14 FB032 FB32 Peak Efficiency gt 97 All specifications are subject to change without notice For wattages other than 32 please contact Nextek Power Systems Inc at Crest Factor lt 1 5 1 877 24VOLTS 5 3 Enclosure Diagram 312 4 mm T23 inl
13. ed States and in other countries throughout the world Rev 040114 i C he Db 380VDG 6 Lamp Ballast Retrofit Kit limstallatiomand UsersiManual gam 6 680 395 and Cher Paba ey T i Carrere maa Pee i China Uo ie 27 0 Lumens 2 0 STANDARDS AND REQUIREMENTS 2 0 STANDARDS AND REQUIREMENTS 2 1 All DC cable types must meet all local and national codes 2 2 Shut off all DC circuit breakers or fuses before installing any unit into the field 3 0 REGULATORY INFORMATION 3 1 NOTE This section contains important information for safety and regulatory requirements 3 2 The Ballast Retrofit Kit should be installed by a qualified technician according to the electrical rules of the country in which the product will be installed 3 3 Nextek ballasts comply with the following EMC standards 3 3 1 Immunity EN61000 6 2 1999 3 3 2 Emissions EN55022 1994 with A1 and A3 Class B1 3 4 A means shall be provided to ensure all the poles are disconnected from the power supply This disconnection shall be incorporated in the fixed wiring 3 5 FCC Requirements 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 Changes or modifications not expressly approved by Nextek Power Systems Inc for compliance could void the user s
14. it on the outside of the luminaire 7 1 16 Ballast is grounded to the enclosure and thus the luminaire Connect the ground wire to the luminaire via the luminaire s grounding terminal screw 7 1 17 Replace any covers or diffusers removed during the conversion installation 7 1 18 Plug any unused openings in the luminaire created by the removal of branch wiring 7 1 19 Affix the included sticker to outside of luminaire near ballast access cover 7 1 20 Connect the power wire from the luminaire to a 83880VDC bus line 7 1 21 Set Dimming Control to operate as follows ve ml M SW1 Open SW1 Closed SW1 Open SW1 Closed O secossa Swzopon smacis swe cose NC SW1 Closed SW1 Open SW1 Open SW1 Open S swaceses suze smeoosa Swzopen 4 1 Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world Rev 040114 C u D 380V DC 6 Lamp Ballast Retrofit Kit Installation EME Sperm a ab0 VOC 5 snarl Bang 305 and Olher Patents Sardi Share Cee Sade mia Ce oe eee lie Cina Up i AE Loe 9 0 NOTES Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world 15 Rev 040114 CN NEXTEK For more information Nextek Power Systems Tel 313 887 1321 Z 461 Burroughs Street Toll free 1 877 24 VOLTS E Merg e Detroit Michigan 48202 Fax 313 887 94
15. na Up ie 27 0 Lumen ABOUT NEXTEK POWER SYSTEMS Nextek Power Systems AC DC integration technology represents a breakthrough in on site electrical management combining the availability of AC power with the quality and efficiency of a DC supply NEXTEK PRODUCT BENEFITS e Easy conversion of AC lighting fixtures to DC powered units e Easy conversion of AC grid power into DC power for commercial building applications e Highly efficient management of peak loads e Future proof lighting and other systems to be developed e Nextek Power Systems Direct Coupling Technology directly connects clean power generated at a building to its electronic loads inside cutting down on over all power consumption boosts electricity generated and stored on site and delivers a robust renewable energy ready network DISCLAIMER Nextek Power Systems has made every reasonable effort to ensure the accuracy of the information in this catalog Nextek Power Systems does not guarantee that the information is error free nor do we make any other representation warranty or guarantee that the information is accurate correct reliable or current Nextek Power Systems Inc reserves the right to make any adjustments to the information contained herein at any time without notice The specifications in this catalog are for reference purposes only and are subject to change without notice Consult Nextek Power Systems for the latest design specifications All trademarks are
16. ncy However potentially hazardous conditions such as inadvertent contact with hazardous voltages may exist while performing servicing and maintenance handling materials or cleaning 1 5 The improper use of electrical extension cords and portable electrical equipment can result in hazardous exposure 1 6 WARNING RISK OF ELECTRICAL SHOCK 1 6 1 This Ballast Retrofit Kit requires knowledge of fluorescent lighting luminaires electrical systems If not qualified do not attempt installation Contact a qualified electrician 1 6 2 This kit is intended only for use with luminaires located in dry locations indoors Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world 5 Rev 040114 E sie dba 6 680 595 and Oher 380VDG 6 Lamp Ballast Retrofit Kit limstallatiomand UsersiManual gam Te aH L ATRPTE CAN maa Peer i China Up ie 27 0 Lumen 1 0 SAFETY 1 6 3 Install this kit only in non IC luminaires that have similar features and dimensions as the photographs and or drawings shown here 1 6 4 The ballast supplied with this kit is intended for use with instant start lampholders Lampholders marked with a circle I meet these requirements Tombstone pins in the lampholder should be shorted 1 6 5 To prevent wiring damage or abrasion do not expose wiring to edges of sheet metal or other sharp objects 1 6 6 Only those open holes indi
17. rly positioned tighten both 2 screws 7 1 10 12 Copyright 2013 2014 all rights reserved by Nextek Power Systems Inc in the United States and in other countries throughout the world Rev 040114 WARNING Risk of fire or electric shock Luminaire wiring and electrical parts may be damaged when drilling for installation of Fluorescent conversion kit Check for enclosed wiring and components as 380VDG 6 Lamp Ballast Retrofit Kit Ynstallation and Users Manual 4 5 and Cher oleh errr C 66H 195 pe i maa Fasiam i Chin Up ie 27 0 Lumens 7 0 INSTALLATION PROCEDURE 7 1 11 LAMPHOLDERS 7 1 11 1 If existing lampholders have a wire shunting the pins go to step 7 1 10 7 1 11 2 If existing lampholders are not shunted then shunt the lampholders with external wire 7 1 12 Connect the lampholder lead wires from the new Nextek ballast as shown on the Ballast Rewiring Schematic to the lampholder wires from the luminaire using wire nuts Figure 7110 Connect with wire nuts N J SOCKETS S 14ay00S See step 7 1 13 for connections BALLAST REWIRING SCHEMATIC 7 1 13 Connect the switch control wires purple orange purple black stripe and orange black stripe to switch as described in the Switch Wiring Tables below If no switching is desired then cap off the orange wires and purple wires with wire nuts separately Switch Type Switch s First Contact Switch s Second Contact Purple SW1
18. ured equipment grounding conductor program 6 4 Installers should be advised 6 4 1 These installation instructions are for use by qualified personnel only 6 4 2 The equipment contains DC voltages 6 4 3 gt NOTE Installers must reference the National Electric Code NEC sections 250 or 690 when required to ensure proper system wiring and grounding compliance In addition all state and federal Occupational Safety and Health Administration OSHA guidelines and regulations must be followed 6 4 4 NOTE Installers must reference the specific site scope and project drawings for additional information and considerations including the system layout and any related electrical drawings 6 4 5 The mounting location is important to the performance and operating life of the unit The environment must be dry and protected from water ingress 6 4 6 The installation is straightforward but it is important each step is done correctly and safely A mistake can lead to dangerous voltage and current levels Be sure to carefully follow each instruction in this section Read all instructions first before beginning installation 6 4 7 The installation instructions are for installation of a negative grounded system National Electrical Code NEC requirements are noted on occasion for convenience however the installer should have a complete understanding of NEC and UL requirements for photovoltaic installations 6 4 8 gt NOTE The retrofit assembly is
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