One Lamp, Two Lamp and CFL Ballasts
Installation and Userʼs Manual
24VDC ONE LAMP BALLAST MODELS:
NB24-T524HO-01D, NB24-T528-01D, NB24-T554-01D, NB24-T832-01D, NB24-BX40-01D
24VDC TWO LAMP BALLAST MODELS:
NB24-T528-02D, NB24-T817-02D, NB24-T832-02D
48VDC TWO LAMP BALLAST MODELS:
KT2-54-R-S-53, NB5353/2R
CFL MODELS:
NB24-CF13-01D, NB24-CF18-01D, NB24-CF26-01D, NB24-CF42-01D
Rev 031114
Please contact Customer Support at 1-800-24VOLTS for further information.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the
United States and in other countries throughout the world.
One Lamp, Two Lamp and CFL Ballasts
Installation and Userʼs Manual
TABLE OF CONTENTS
ABOUT NEXTEK POWER SYSTEMS
3
INTRODUCTION / OVERVIEW
4
1.0
SAFETY
5
2.0
STANDARDS & REQUIREMENTS
6
3.0
REGULATORY INFORMATION
7
4.0
TRAINING
7
5.0
FEATURES
8
6.0
SPECIFICATIONS
9
7.0
GENERAL REQUIREMENTS
10
8.0
INSTALLATION PROCEDURE
12
8.1
24V ONE-LAMP BALLAST MODELS
12
8.2
24V TWO-LAMP BALLAST MODELS
16
8.3
CFL BALLAST MODELS
20
8.4
48V TWO-LAMP BALLAST MODELS
23
8.5
WIRING A 2-LAMP BALLAST TO
AN E-BALLAST FIXTURE
26
9.0
CFL BALLAST INSTALLATION TIP SHEET
10.0 TROUBLESHOOTING
28
11.0 NOTES
29
For more information:
2
27
Nextek Power Systems
461 Burroughs Street
Detroit, Michigan 48202
Tel: 313-887-1321
Toll free: 1 (877) 24-VOLTS
Fax: 313-887-9433
www.nextekpower.com
info@nextekpower.com
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
Installation and Userʼs Manual
ABOUT NEXTEK POWER SYSTEMS
Nextek Power Systems AC/DC integration technology represents a breakthrough in onsite electrical management, combining the availability of AC power with the quality and
efficiency of a DC supply.
NEXTEK PRODUCT BENEFITS
•
Easy conversion of AC lighting fixtures to DC-powered units
•
Easy conversion of AC grid power into DC power for commercial building
applications
•
Highly efficient management of peak loads
•
Future-proof lighting and other systems to be developed
•
Nextek Power Systems Direct Coupling® Technology, directly connects clean
power generated at a building to its electronic loads inside cutting down on overall 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 either the exclusive property of
Nextek Power Systems, Inc. or other companies. Copyright © 2012-2014 by Nextek
Power Systems, Inc. in the United States and other countries throughout the world.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
3
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One Lamp, Two Lamp and CFL Ballasts
Installation and Userʼs Manual
INTRODUCTION
Nextek Ballasts
• Nextekʼs Ballast Installation Kit converts existing luminaires from AC power to safe, lowvoltage Direct Current (DC) power by simply replacing the ballasts.
• Convert luminaires without replacing bulbs or system wiring. Nextek ballasts are sized to use
pre-existing mounting holes and hardware too.
• The simple procedure takes only minutes to complete.
Nextek ballasts in a Direct Current power system.
4
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
1.0
Installation and Userʼs Manual
SAFETY
1.1 SAVE THESE INSTRUCTIONS– This manual contains important safety and
operating instructions for the Nextek Ballast Installation 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 Installation 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 It is 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 efficiency. 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 Installation Kit requires knowledge of fluorescent lighting
luminaires electrical systems. If not qualified, do not attempt installation.
Contact a qualified electrician.
1.6.2 Install this kit only in luminaires that have similar features and dimensions
as the photographs and/or drawings shown here.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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Installation and Userʼs Manual
SAFETY
1.6.3 The ballast supplied with this kit is not for use with instant-start
lampholders. Do not short between the pins in the lampholder. (Not
applicable for BIAX lamps.)
1.6.4 To prevent wiring damage or abrasion, do not expose wiring to edges of
sheet metal or other sharp objects.
1.6.5 Only those open holes indicated 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.
1.6.6 A listed Class 2 24VDC or 48VDC output supply, such as a Nextek PSM,
must be used as a power source for the Nextek low voltage ballast.
1.6.7 These Nextek low voltage ballasts are intended for use only with non-IC
(Luminaires not intended for Insulation Contact).
1.6.7 Before wiring 24VDC or 48VDC supply to ballasts, remove any old AC
wiring, including any ground wires, between the line voltage ballast and
the nearest junction box.
1.7
DANGER – TO REDUCE THE RISK OF FIRE OR ELECTRIC
SHOCK, CAREFULLY FOLLOW THESE INSTRUCTIONS
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 ballasts 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 Installation Kit is to be connected to DC circuits only.
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.
6
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
3.0
Installation and Userʼs Manual
REGULATORY INFORMATION
3.1
NOTE: This section contains important information for safety and
regulatory requirements.
3.2 The Ballast Installation 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 authority to operate the equipment.
Note:
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 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:
4.0
•
Reorient or relocate the receiving antenna.
•
Increase the separation between the equipment and receiver.
•
Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
•
Consult the dealer or an experienced radio/TV technician for help.
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 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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Installation and Userʼs Manual
BALLAST FEATURES
• Low-voltage, 2 wire (class 2) 0-10Vdc
control technology turns lamps off (<1 Volts)
at the bottom of the voltage range. Lamps
can be switched back on to a previous
dimming level instantly.
• Programmed rapid start design: Lamps turn
on to any dimmed level without flashing to
full brightness.
• UL 2108 classified.
• State-of-the-art Phase Control operation
resulting in continuous, flicker-free dimming
from 100% to 10%.
• Inherent Thermal Protection
• Type 1, Class P, Sound rated A
• USL 935 Listed.
• Input voltage is rated class 2, which does
not require grounding. No provision exists
for grounding. (Input 24V DC, <4A)
MODELS LIST
24VDC ONE LAMP BALLAST MODELS:
NB24-T524HO-01D, NB24-T528-01D, NB24-T554-01D, NB24-T832-01D, NB24-BX40-01D
24VDC TWO LAMP BALLAST MODELS:
NB24-T528-02D, NB24-T817-02D, NB24-T832-02D
48VDC TWO LAMP BALLAST MODELS:
KT2-54-R-S-53, NB5353/2R
CFL MODELS:
NB24-CF13-01D, NB24-CF18-01D, NB24-CF26-01D, NB24-CF42-01D
Kit contents:
1. Ballast
2. Installation and User Manual
3. Installation hardware
8
NOTE: This kit is only for use in a UL 1598 listed fixture
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
6.0
Installation and Userʼs Manual
TECHNICAL SPECIFICATIONS
T528-1Lamp
T528-2Lamp
T524HO-1Lamp
T528-2Lamp
T832-1Lamp
T817-2Lamp
T832-2Lamp
1.21 Amp @
24V DC
1.98 Amp @
24V DC
1.13 Amp @
24V DC
1.98 Amp @
24V DC
1.35 Amp @
24V DC
1.38 Amp @
24V DC
1.99 Amp @
24V DC
Operating
Temperature:
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
Maximum
Ballast Factor:
1.0
.075
1.0
.075
1.0
1.0
.075
Peak Efficiency:
95%
95%
95%
95%
94%
94%
94%
Crest Factor:
<1.55
<1.55
<1.55
<1.55
<1.55
<1.55
<1.55
Operating
Voltage:
Operating
Current:
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
(nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10%
Analog
Dimming:
0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10
V DC - Dimming V DC - Dimming V DC - Dimming V DC - Dimming V DC - Dimming V DC - Dimming V DC - Dimming
Dimensions:
1.10"W x
1.10"W x
1.10"W x
1.10"W x
1.10"W x
1.10"W x
1.10"W x
0.96"H x 9.57"L 0.96"H x 9.57"L 0.96"H x 9.57"L 0.96"H x 9.57"L 0.96"H x 9.57"L 0.96"H x 9.57"L 0.96"H x 9.57"L
Weight:
16 oz.
16 oz.
16 oz.
16 oz.
16 oz.
16 oz.
16 oz.
Construction:
Steel
Steel
Steel
Steel
Steel
Steel
Steel
F28T5
F28T5
F24T5HO
F28T5
Operated With:
40BIAX-1Lamp
CFL-13**
1.6 Amp @
24V DC
Operating
Temperature:
Maximum
Ballast Factor:
F32T8, FB032, F17T8, F18T8 F32T8, FB032,
F32T8ES, FB32*
F32T8ES, FB32*
*For wattages other than 32, please contact Nextek Power Systems, Inc. at 1-877-24VOLTS
CFL-18**
CFL-26**
CFL-32/42**
KT-2-54-RS-53
NB5353/2R
0.65 Amp @
24V DC
0.84 Amp @
24V DC
1.10 Amp @
24V DC
1.54 Amp @
24V DC
2.2 Amp @
54V DC
1.0 Amp @
54V DC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
0ºC-49ºC
1.0
1.0
1.0
1.0
0.9
1.0
0.88
Peak Efficiency:
95%
85%
87%
89%
87%@32W,
93%@42W
Crest Factor:
<1.55
<1.55
<1.55
<1.55
<1.55
<1.70
meets ANSI
n/a
n/a
Operating
Voltage:
Operating
Current:
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
48 V DC
54 V DC
(nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10% (nominal)±10%
Analog
Dimming:
0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10 0 V DC - off, 1-10
V DC - Dimming V DC - Dimming V DC - Dimming V DC - Dimming V DC - Dimming
Dimensions:
1.10"W x
1.10"W x
2.96"W x
2.96"W x
2.96"W x
2.25"W x
2"W x 1.125"H
0.96"H x 9.57"L 0.96"H x 9.57"L 1.27"H x 5.03"L 1.27"H x 5.03"L 1.27"H x 5.03"L 1.40"H x 6.25"L
x 3.125"L
Weight:
16 oz.
16 oz.
16 oz.
16 oz.
16 oz.
8 oz.
10.5 oz.
Construction:
Steel
Steel
Steel
Steel
Steel
Steel
Steel
F40BX,
F39BX, FT40
CFQ13, CFT13
CFQ18,
CFT18, CFD18
CFT26
CFT32, CFT42
F54T5HO
F54T8
Operated With:
**For CFL Ballasts, heat and smoke release testing in accordance with UL 2043 was not considered necessary due to the small mass of the
exposed polymeric parts. Weight of exposed polymeric parts is less than 5 grams each. CFL Ballasts are Suitable for use in Air Handling Spaces.
All specifications are subject to change without notice.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
GENERAL REQUIREMENTS
7.1 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.
7.2 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.
7.3 Two approved methods of protecting the worker from a ground fault, in addition
to other requirements for equipment-grounding conductors, are:
7.3.1 Use of ground fault circuit interrupters (GFCI)
7.3.2 An assured equipment grounding conductor program
7.4 Installers should be advised:
7.4.1 These installation instructions are for use by qualified personnel only.
NOTE: Installers must reference the National Electric Code (NEC)
sections
250 or 690, when required, to ensure proper system wiring
7.4.2 The equipment contains DC voltages.
7.4.3
and grounding compliance. In addition, all state and federal
Occupational Safety and Health Administration (OSHA) guidelines
and regulations must be followed.
NOTE: Installers must reference the specific site scope and project
drawings
for additional information and considerations, including the
7.4.4
system layout and any related electrical drawings.
7.4.5 The mounting location is important to the performance and operating life
of the unit. The environment must be dry and protected from water
ingress.
7.4.6 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.
7.4.7 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.
10
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
7.0
Installation and Userʼs Manual
GENERAL REQUIREMENTS
7.5 Recommended Tools
7.5.1 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
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
8.1 24VDC ONE-LAMP BALLAST MODELS
T5 1-Lamp Ballast
24W T5 HO (NB24-T524HO01D)
28W T5 (NB24-T528-01D)
54W T5 (NB24-T554-01D)
T8 1-Lamp Ballast
32W T8 (NB24-T832-01D)
40W BIAXTM
1-Lamp Ballast
40W BIAX (NB24-BX40-01D)
24VDC ONE-LAMP BALLAST WIRING DIAGRAM
NOTE: If an AC ballast has been previously installed in the location,
refer
to the Nextek Ballast Retrofit Kit Installation and User Manual,
Lamp holder must not be shorted
8.1.1
available for download at www.nextekpower.com.
8.1.2
WARNING - Shock Hazard
At the supply panel, disconnect power to the luminaire(s).
WARNING - Risk of fire or electric shock. Luminaire wiring and
electrical parts may be damaged when drilling for installation of unit.
Check for enclosed wiring and components.
8.1.3 Mount the new Nextek low voltage 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.
8.1.4 Prepare the ballast mounting location: Refer to the luminaire
manufacturer’s instructions or drawings to identify the mounting locations
and any specific electrical location requirements or special instructions.
8.1.4.1 Select a ballast mounting location within the luminaire that leaves
sufficient length to route the ballast’s wires to the fixture
connections.
8.1.5 Slotted mounting holes for the ballasts are located on the flanges that
protrude from the bottom of the unit housing.
8.1.6 For pre-existing mounting studs or holes:
8.1.6.1 Carefully align the ballast slot to one mounting hole or stud and
insert a sheet metal screw.
12
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Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
8.1.6.2 Do not tighten the screw completely. Leave a 1/4" (6 mm) gap
between the mounting surface and screw head.
8.1.6.3 Carefully align the ballast slot to one mounting hole or stud and
insert a sheet metal screw.
8.1.6.4 When the ballast is properly positioned, tighten both (2) screws.
8.1.6.5 Proceed to step 8.1.8.
8.1.7 For a surface with no pre-existing mounting studs or holes:
8.1.7.1 Place a mark on the mounting surface for one of the mounting
holes in accordance with the luminaire manufacturer’s
instructions or drawings.
8.1.7.2 Use a self-tapping sheet metal screw to insert the first screw at
the mark.
8.1.7.3 Do not tighten the screw completely. Leave a 1/4" (6 mm) gap
between the mounting surface and screw head.
8.1.7.4 Mark the second mounting hole location for the ballast.
8.1.7.5 Carefully align the ballast slot to the second mounting hole and
insert a sheet metal screw.
8.1.7.6 When the ballast is properly positioned, tighten both (2) screws.
Notes Regarding Lampholders:
8.1.8 Ballast Wiring Instructions
8.1.8.1
8.1.8.1.1 If lampholders are not shunted, or the ballast being
installed is a BIAX, then go to step 8.1.8.2.
8.1.8.1.2 If lampholders have a wire shunting the pins, remove
the wire and go to step 8.1.8.2.
8.1.8.1.3 If lampholders are shunted, but do not have an external
wire shunting the pins, then replace the lampholders
with unshunted ones, following the manufacturer’s
directions.
8.1.8.2 Connect the lampholder lead wires from the Nextek ballast as
shown on the Ballast Wiring Schematic (below) to the lampholder
connectors.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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INSTALLATION PROCEDURE
8.1.8.3
BALLAST WIRING SCHEMATIC
See step 8.1.8 for
connections
NOTE: Route wires within the Luminaire to maintain 1/4
inch
separation between lampholder wires and the low
voltage input power and control wires, using included wire
ties, if necessary. Failure to maintain these separations will
cause dimming performance problems.
8.1.8.4 Connect the dimming wires (purple and gray) to the dimming
control, if used. If not used, cap off purple and gray wires
individually. (Note: Shorting purple and gray wires will prevent
ballast from ever turning on.)
8.1.8.5 Connect Nextek low voltage ballast input leads (black wires) to
one of the following power inputs:
8.1.8.5.1 Tyco Electronics Load (Device) Cable Assembly (TE
Part 2106718-x) for use with emerge standardized low
voltage suspended ceiling grid, or to
8.1.8.5.2 A suitably-rated 90ºC cable between 12 and 18 AWG,
terminating outside the luminaire, for example with a
female 2-position Tyco Electronics Universal MATE-NLOK, or functional equivalent including strain relief, or
directly to the next luminaire.
There is no equipment ground in a class 2 wiring
NOTE:
system. Do not attach either 24V DC conductor to any
Polarity (+ and –) does not matter on Nextek ballast
input.
8.1.8.6
grounding post in the luminaire. Attach 24V DC conductors
to the ballast input wires only. The ballast automatically
adjusts its polarity.
14
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
8.1.8.7
NOTE: Class 2 circuits are power limited to 100 Watts. Do
not
attempt to attach more load on a single circuit,
consulting the ballast and Class 2 power supply
manufacturers’ specifications.
8.1.9 Replace any covers or diffusers removed during the installation.
8.1.10 Plug any unused openings in the luminaire.
8.1.11 Connect the power wire from the luminaire to:
8.1.11.1 EMerge Registered Busbar grid if terminated in EMerge Load
Cable Assembly, or
8.1.11.2 Directly to Nextek PSM if terminated using the MATE-N-LOK
type connector.
8.1.11.3 Directly to the adjacent luminaire.
8.1.12 Set Dimming Control to operate as follows:
0-1 Volts = Lamp off
1 Volt = Lamps ON- lowest dim level
1 – 10 Volts = Increasing in brightness with voltage increase
10 Volts = Lamps ON- Full brightness
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INSTALLATION PROCEDURE
8.2 24VDC TWO-LAMP BALLAST MODELS
T5 2-Lamp Ballast
28W T5 (NB24-T528-02D)
T8 2-Lamp Ballast
17W T8 (NB24-T817-02D)
32W T8 (NB24-T832-02D)
24VDC TWO-LAMP BALLAST WIRING DIAGRAM
8.2.1
NOTE: If an AC ballast has been previously installed in the location,
refer
to the Nextek Ballast Retrofit Kit Installation and User Manual,
available for download at www.nextekpower.com.
8.2.2
WARNING - Shock Hazard
At the supply panel, disconnect power to the luminaire(s).
WARNING - Risk of fire or electric shock. Luminaire wiring and
electrical parts may be damaged when drilling for installation of unit.
Check for enclosed wiring and components.
8.2.3 Mount the new Nextek low voltage 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.
8.2.4 Prepare the ballast mounting location: Refer to the luminaire
manufacturer’s instructions or drawings to identify the mounting locations
and any specific electrical location requirements or special instructions.
8.2.4.1 Select a ballast mounting location within the luminaire that leaves
sufficient length to route the ballast’s wires to the fixture
connections.
8.2.5 Slotted mounting holes for the ballasts are located on the flanges that
protrude from the bottom of the unit housing.
8.2.6 For pre-existing mounting studs or holes:
16
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
8.2.6.1 Carefully align the ballast slot to one mounting hole or stud and
insert a sheet metal screw.
8.2.6.2 Do not tighten the screw completely. Leave a 1/4" (6 mm) gap
between the mounting surface and screw head.
8.2.6.3 Carefully align the ballast slot to one mounting hole or stud and
insert a sheet metal screw.
8.2.6.4 When the ballast is properly positioned, tighten both (2) screws.
8.2.6.5 Proceed to step 8.2.8.
8.2.7 For a surface with no pre-existing mounting studs or holes:
8.2.7.1 Place a mark on the mounting surface for one of the mounting
holes in accordance with the luminaire manufacturer’s
instructions or drawings.
8.2.7.2 Use a self-tapping sheet metal screw to insert the first screw at
the mark.
8.2.7.3 Do not tighten the screw completely. Leave a 1/4" (6 mm) gap
between the mounting surface and screw head.
8.2.7.4 Mark the second mounting hole location for the ballast.
8.2.7.5 Carefully align the ballast slot to the second mounting hole and
insert a sheet metal screw.
8.2.7.6 When the ballast is properly positioned, tighten both (2) screws.
Notes Regarding Lampholders:
8.2.8 Ballast Wiring Instructions
8.2.8.1
8.2.8.1.1 If lampholders are not shunted, or the ballast being
installed is a BIAX, then go See
to step
8.2.8.2.
step
8.2.8.4
for connections
8.2.8.1.2 If lampholders have a wire shunting the pins, remove
the wire and go to step 8.2.8.2.
8.2.8.1.3 If lampholders are shunted, but do not have an external
wire shunting the pins, then replace the lampholders
with unshunted ones, following the manufacturer’s
directions.
8.2.8.2 Connect the lampholder lead wires from the Nextek ballast as
shown on the Ballast Wiring Schematic (below) to the lampholder
connectors.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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INSTALLATION PROCEDURE
8.2.8.3
BALLAST WIRING SCHEMATIC
NOTE: Route wires within the Luminaire to maintain 1/4
inch
separation between lampholder wires and the low
voltage input power and control wires, using included wire
ties, if necessary. Failure to maintain these separations will
cause dimming performance problems.
NOTE: For single lamp operation, cap off yellow wires.
Attach
both blue wires to one end and both red wires to
other end.
8.2.8.4 Connect the dimming wires (purple and gray) to the dimming
control, if used. If not used, cap off purple and gray wires
individually. (Note: Shorting purple and gray wires will prevent
ballast from ever turning on.)
8.2.8.5 Connect Nextek low voltage ballast input leads (black wires) to
one of the following power inputs:
8.2.8.5.1 Tyco Electronics Load (Device) Cable Assembly (TE
Part 2106718-x) for use with emerge standardized low
voltage suspended ceiling grid, or to
8.2.8.5.2 A suitably-rated 90ºC cable between 12 and 18 AWG,
terminating outside the luminaire, for example with a
female 2-position Tyco Electronics Universal MATE-NLOK, or functional equivalent including strain relief, or
directly to the next luminaire.
There is no equipment ground in a class 2 wiring
NOTE:
system. Do not attach either 24V DC conductor to any
Polarity (+ and –) does not matter on Nextek ballast input.
8.2.8.6
grounding post in the luminaire. Attach 24V DC conductors
18
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
NOTE: Class 2 circuits are power limited to 100 Watts. Do
not
attempt to attach more load on a single circuit,
to the ballast input wires only. The ballast automatically
adjusts its polarity.
8.2.8.7
consulting the ballast and Class 2 power supply
manufacturers’ specifications.
8.2.9 Replace any covers or diffusers removed during the installation.
8.2.10 Plug any unused openings in the luminaire.
8.2.11 Connect the power wire from the luminaire to:
8.2.11.1 EMerge Registered Busbar grid if terminated in EMerge Load
Cable Assembly, or
8.2.11.2 Directly to Nextek PSM if terminated using the MATE-N-LOK
type connector.
8.2.11.3 Directly to the adjacent luminaire.
8.2.12 Set Dimming Control to operate as follows:
0-1 Volts = Lamp off
1 Volt = Lamps ON- lowest dim level
1 – 10 Volts = Increasing in brightness with voltage increase
10 Volts = Lamps ON- Full brightness
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
8.3 CFL LAMP BALLAST MODELS
13W CFL (NB24-CF13-01D)
18W CFL (NB24-CF18-01D)
26W CFL (NB24-CF26-01D)
32/42W CFL (NB24-CF42-01D)
CFL BALLAST WIRING DIAGRAM
8.3.1
NOTE: If an AC ballast has been previously installed in the location,
refer
to the Nextek Ballast Retrofit Kit Installation and User Manual,
available for download at www.nextekpower.com.
8.3.2
WARNING - Shock Hazard
At the supply panel, disconnect power to the luminaire(s).
WARNING - Risk of fire or electric shock. Luminaire wiring and
electrical parts may be damaged when drilling for installation of unit.
Check for enclosed wiring and components.
Notes Regarding Lampholders:
8.3.3 Ballast Wiring Instructions
8.3.3.1
8.3.3.1.1 Existing lampholders are assumed to be standard four
(4) pin lampholders.
8.3.3.1.2 Not for use with luminaires that use standard line
voltage Edison bases with integral ballasts.
8.3.4 Route the DC power input wires through a wire restraint into the
enclosure at least 4 inches past the connector, and tighten the restraint
screws. DC power input wires can be one of the following:
8.3.4.1 Tyco Electronics Load (Device) Cable Assembly (TE Part
2106718-x) for use with emerge standardized low voltage
suspended ceiling grid, or to
8.3.4.2 a suitably-rated 90ºC cable between 12 and 18 AWG,
terminating outside the luminaire, for example with a female 220
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
position Tyco Electronics Universal MATE-N-LOK, or functional
equivalent including strain relief, or directly to the next luminaire.
Polarity (+ and –) does not matter on Nextek ballast input.
BALLAST REWIRING SCHEMATIC
8.3.5 Connect the black wires to the ballast power terminals.
NOTE: There is no equipment ground in a class 2 wiring
system.
Do not attach either 24V DC conductor to any
8.3.6 Connect the blue and red lamp wires to the ballast terminals.
8.3.6.1
grounding post in the luminaire. Attach 24V DC conductors
to the ballast input wires only. The ballast automatically
adjusts its polarity.
8.3.6.2
NOTE: Class 2 circuits are power limited to 100 Watts. Do
not
attempt to attach more load on a single circuit,
consulting the ballast and Class 2 power supply
manufacturers’ specifications.
8.3.7 Replace the ballast wiring enclosure cover, and mount the new Nextek
low voltage ballast using existing studs or screws. If necessary, secure
ballasts using appropriately sized sheet metal screws. If no existing hole
exists at the correct mounting location, use a self-tapping sheet metal
screw.
8.3.8 Connect gray and purple control wires to the ballast terminals if a control
system is in use. These will be connected to an exterior control box.
8.3.9 Replace any covers or diffusers removed during the installation.
8.3.10 Plug any unused openings in the luminaire.
8.3.11 Set Dimming Control to operate as follows:
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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INSTALLATION PROCEDURE
0-1 Volts = Lamp off
1 Volt = Lamps ON- lowest dim level
1 – 10 Volts = Increasing in brightness with voltage increase
10 Volts = Lamps ON- Full brightness
22
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
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Installation and Userʼs Manual
INSTALLATION PROCEDURE
8.4 48VDC TWO-LAMP BALLAST MODELS
T5 2-Lamp Ballast
KT2-54-R-S-53
T8 2-Lamp Ballast
NB5353/2R
KT2-54-R-S-53 48VDC TWO-LAMP BALLAST WIRING DIAGRAM
SWITCH
MODULAR JACK
ON
OFF
RED +
RED
BLACK -
NB5353/2R 48VDC TWO-LAMP BALLAST WIRING DIAGRAM
Not actual sizes
SWITCH
MODULAR JACK
ON
OFF
RED +
BLACK -
8.4.1
8.4.2
NOTE: If an AC ballast has been previously installed in the location,
refer to the Nextek Ballast Retrofit Kit Installation and User Manual,
available for download at www.nextekpower.com.
Not actual sizes
WARNING - Shock Hazard
At the supply panel, disconnect power to the luminaire(s).
WARNING - Risk of fire or electric shock. Luminaire wiring and
electrical parts may be damaged when drilling for installation of unit.
Check for enclosed wiring and components.
23
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
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Installation Manual
INSTALLATION PROCEDURE
8.4.3 Mount the new Nextek low voltage 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.
8.4.4 Prepare the ballast mounting location: Refer to the luminaire
manufacturer’s instructions or drawings to identify the mounting locations
and any specific electrical location requirements or special instructions.
8.4.4.1 Select a ballast mounting location within the luminaire that leaves
sufficient length to route the ballast’s wires to the fixture
connections.
8.4.5 Mounting holes (KT2-54-R-S-53) or slots (NB5353/2R) for the ballasts
are located on the flanges that protrude from the bottom of the unit
housing.
8.4.6 For pre-existing mounting studs or holes:
8.4.6.1 Carefully align the ballast slot to one mounting hole or stud and
insert a sheet metal screw.
8.4.6.2 Do not tighten the screw completely. Leave a 1/4" (6 mm) gap
between the mounting surface and screw head.
8.4.6.3 Carefully align the ballast slot to one mounting hole or stud and
insert a sheet metal screw.
8.4.6.4 When the ballast is properly positioned, tighten both (2) screws.
8.4.6.5 Proceed to step 8.4.8.
8.4.7 For a surface with no pre-existing mounting studs or holes:
8.4.7.1 Place a mark on the mounting surface for one of the mounting
holes in accordance with the luminaire manufacturer’s
instructions or drawings.
8.4.7.2 Use a self-tapping sheet metal screw to insert the first screw at
the mark.
8.4.7.3 Do not tighten the screw completely. Leave a 1/4" (6 mm) gap
between the mounting surface and screw head.
8.4.7.4 Mark a second mounting hole location for the ballast.
8.4.7.5 Carefully align the ballast slot to a second mounting hole and
insert a sheet metal screw. Repeat for additional holes if needed.
8.4.7.6 When the ballast is properly positioned, insert and tighten
remaining screws.
24
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
8.0
Installation Manual
INSTALLATION PROCEDURE
Notes Regarding Lampholders:
8.4.8 Ballast Wiring Instructions
8.4.8.1
8.4.8.1.1 If lampholders are not shunted, or the ballast being
installed is a BIAX, then go to step 8.4.8.2.
8.4.8.1.2 If lampholders have a wire shunting the pins, remove
the wire and go to step 8.4.8.2.
8.4.8.1.3 If lampholders are shunted, but do not have an external
wire shunting the pins, then replace the lampholders
with unshunted ones, following the manufacturer’s
directions.
8.4.8.2 Connect the lampholder lead wires from the Nextek ballast as
shown on the Ballast Wiring Diagrams (8.4) to the lampholder
connectors.
8.4.8.3
NOTE: For single lamp operation, cap off yellow wires.
Attach
both blue wires to one end and both red wires to
other end.
8.4.8.4 Connect Nextek low voltage ballast input leads (black/red wires)
to one of the following power inputs:
8.4.8.4.1 Tyco Electronics Load (Device) Cable Assembly (TE
Part 2106718-x) for use with emerge standardized low
voltage suspended ceiling grid, or to
8.4.8.4.2 A suitably-rated 90ºC cable between 12 and 18 AWG,
terminating outside the luminaire, for example with a
female 2-position Tyco Electronics Universal MATE-NLOK, or functional equivalent including strain relief, or
directly to the next luminaire.
Polarity (+ and –) does not matter on Nextek ballast input.
8.4.8.5 In lieu of connecting wires, plug the RJ11 connector into an
appropriate socket.
8.4.8.6 To connect the ballast to a toggle switch, you will need to install
an RJ-11 Modular Jack Plate (Nextek #654 or equivalent), and
mount the jack plate on a single gang box. The jack
plate is typically mounted above a drop ceiling.
MODULAR JACK
8.4.8.6.1 Mount the toggle switch (if not already done).
8.4.8.6.2 Connect the switch to the Red and Green
contacts of the jack plate.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
CEILING
WIRES TO JACK
TERMINALS R & G
ON
OFF
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INSTALLATION PROCEDURE
8.4.8.7
NOTE: There is no equipment ground in a class 2 wiring
system.
Do not attach either 24V DC conductor to any
grounding post in the luminaire. Attach 24V DC conductors
to the ballast input wires only. The ballast automatically
adjusts its polarity.
8.4.8.8
NOTE: Class 2 circuits are power limited to 100 Watts. Do
not
attempt to attach more load on a single circuit,
consulting the ballast and Class 2 power supply
manufacturers’ specifications.
8.4.9 Replace any covers or diffusers removed during the installation.
8.4.10 Plug any unused openings in the luminaire.
8.4.11 Connect the power wire from the luminaire to:
8.4.11.1 EMerge Registered Busbar grid if terminated in EMerge Load
Cable Assembly, or
8.4.11.2 Directly to Nextek PSM if terminated using the MATE-N-LOK
type connector.
8.4.11.3 Directly to the adjacent luminaire.
8.5 WIRING A 2-LAMP BALLAST TO AN E-BALLAST FIXTURE
8.5.1 Follow the wiring diagram below to ensure correct connections.
2 LAMP BALLAST
YELLOW (2)
RED (2)
BLUE (2)
E-BALLAST
RED (1)
YELLOW (2)
LAMP #1
E-LAMP #2
26
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
9.0
Installation and Userʼs Manual
CFL BALLAST INSTALLATION TIP SHEET
9.1 CFL LAMP BALLAST MODELS
Based on light fixture assembly and operation experiences, the following
represents a simple check list approach to assure maximum quality and
operability for finished product that contains Nextek DC ballasts.
9.1.1 Ballast Location
9.1.1.1 Place ballast in a convenient location for future service access.
9.1.1.2 Where there are multiple ballasts, locate ballasts in a cluster
fashion where all ballasts can be serviced conveniently.
9.1.2 Wiring
9.1.2.1 Locate unattached dimming wires (grey and purple), so that they
can be easily accessed from the standard fixture access panels
without having to disassemble entire fixture.
9.1.2.2 Use of push-in wire connectors, (Ideal brand or equal), is
recommended as opposed to twist-on wire nuts.
9.1.2.3 In all cases, specific care must be given to proper stripping of
wire insulation. Confirm proper length of exposed conductors and
that the stripping process has not cut into or otherwise damaged
the wire conductor.
9.1.2.4 Care must be taken for neat and organized wire management
within the fixture. Use of tie straps and clustering of loose cabling
should be performed.
9.1.2.5 In no case shall any exposed conductors of dimming or other
wires be allowed to remain once fixture is closed.
9.1.3 Controls
9.1.3.1 It is expected that controls will be installed in the field for all
fixtures. Care should be taken in final fixture assembly to
accommodate a variety of controls, (dimming, occupancy
sensing, daylight sensing).
9.1.4 Testing / General
9.1.4.1 Finished unit should be tested for basic operation before final
packing or shipping.
9.1.4.2 Lamps should be new and in good operating condition.
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
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28
Installation Manual
TROUBLESHOOTING
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
Rev. 031114
One Lamp, Two Lamp and CFL Ballasts
11.0
Installation and Userʼs Manual
NOTES
Copyright 2012-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.
29
Rev. 031114
For more information:
Nextek Power Systems
461 Burroughs Street
Detroit, Michigan 48202
www.nextekpower.com
Tel: 313-887-1321
Toll free: 1 (877) 24-VOLTS
Fax: 313-887-9433
info@nextekpower.com