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650135-005 INSTRUCTION SHEET
Installation Instructions for Mercmaster™ III Luminaires
FOR PROPER AND SAFE INSTALLATION OF THIS PRODUCT, PLEASE READ THE FOLLOWING INSTRUCTIONS.
Applications
• Marine and wet locations;
• Areas where ammable gases and vapors or combustible dusts are present under conditions dened by the ratings below;
• Non-hazardous locations where severe weather conditions, excessive moisture, dirt, dust, corrosive atmospheres, or high ambient
temperatures are encountered.
Ratings
• Class I, Division 2, Groups A, B, C, D
• Class II, Division 1, Groups E, F, G
• Class III
• Simultaneous Exposure (Class I, Division 2/Class II, Division 1)
• Type 3R
• Type 4X
• IP66
• Marine, Outside Type (Salt Water)
Product Safety
Signal Words Defined
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous
situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury. NOTICE is used to address practices not related to physical injury.
Safety Instructions
WARNING:
• Do not open or remove the luminaire with the circuit energized.
• Failure to ground this luminaire can result in an electric shock, which may be fatal.
• Do not use this luminaire on ungrounded circuits. Failure to ground the luminaire can result in an electric shock, which may be fatal.
CAUTION:
• When installing in a hazardous location, it is necessary that the globe be in place and that the unit be tightly closed.
• Luminaires with the optional photocontrol or quartz auxiliary lamp do not comply with UL requirements for use in classied locations.
NOTICE:
• This luminaire is designed for and should be installed in accordance with the National Electrical Code and all applicable local codes.
• The globe and reector should be cleaned periodically to maintain lighting efciency.
• Orient hinges and latches 90° from the aiming direction desired for the angle reector. This applies to ceiling, wall, and stanchion
mounting hoods.
• All unused conduit plugs and conduit runs must have pipe lubricant/sealant applied to the threads and then securely tightened.
This will prevent water entry into the luminaire through the pipe threads. Use Appleton TLC-3 lubricant/sealant.
Appleton • 1.800.621.1506 • www.appletonelec.com 650135-005 Rev. K 07/13 • Page 1 of 8
Mounting Hoods
Pendant (KPAF-75, KPAF-100, KPA-75, KPA-100)
Mounting:
1. Thread the pendant hood onto a 3/4 inch or 1 inch conduit stem. NOTE: A brace is required on conduit stems longer than 12 inches
(NEC requirement).
2. Tighten the set screw inside the hood.
SET SCREW
FLEXIBLE
SET SCREW
STANDARD
Pendant Cone (KPCH-75, KPCH-100)
Mounting:
1. Thread the pendant cone hood onto a 3/4 inch or 1 inch conduit stem. NOTE: A brace is required on conduit stems longer than 12
inches (NEC requirement).
2. Tighten the set screw outside the hood.
SET SCREW
Ceiling (KPC-75, KPC-100)
Mounting:
1. Bolt the ceiling hood directly to a structural member; thread onto a 3/4 inch or 1 inch conduit stem; or bolt to a ush mounted
junction box (see NOTES).
2. Remove unused conduit plugs and reinstall with pipe sealant.
3-12"
TYP
13-7/8"
5 CONDUIT ENTRIES, 4 CONDUIT PLUGS
45°
12-7/8"
NOTES:
• Four drill marks on the 3-1/2 inch pitch diameter are provided for junction box mounting.
• Install the junction box gasket (supplied) between the junction box and the ceiling hood.
Appleton • 1.800.621.1506 • www.appletonelec.com
650135-005 Rev. K 07/13 • Page 2 of 8
Wall (KPWB-75, KPWB-100)
Mounting:
1. Bolt the wall hood to a structural member.
2. Remove unused conduit plugs and reinstall with pipe sealant.
16.96"
10.93"
12.03"
5 CONDUIT ENTRIES, 4 CONDUIT PLUGS
3.36"
1.68"
0.31" DIA (4 HOLES)
4.06"
2.03"
25° Stanchion (KPS-125, KPS-150)
Mounting:
1. Thread the stanchion hood onto a 1-1/4 inch or 1-1/2 inch conduit stem. NOTE: Five full threads must be engaged.
2. Determine the orientation and tighten the set screw.
15.24"
9.21"
12.03"
SET SCREW
25°
7.50"
90° Stanchion (KPST-125, KPST-150)
Mounting:
1. Thread the stanchion hood onto a 1-1/4 inch or 1-1/2 inch conduit stem. NOTE: Five full threads must be engaged.
2. Determine the orientation and tighten the set screw.
17.20"
9.79"
SET
SCREW
12.06"
Appleton • 1.800.621.1506 • www.appletonelec.com 650135-005 Rev. K 07/13 • Page 3 of 8
Installation
PRODUCT EXAMPLE (OPTIONS MAY VARY)
HINGE
HINGE
PIN
SET
SCREW
GROUND
WIRE
INSTALLATION
HOOD
GROUND
SCREW
GASKET
LATCH
SCREW
LATCH
HEX
Installing & Wiring:
1. Feed the proper temperature supply wire into the mounting hood. See the product nameplate for supply wire requirements.
2. Hang the ballast housing on the hinge; secure with the hinge pin.
3. Connect the power to the proper ballast lead. See “Wiring Diagrams”. NOTE: Leave all unused ballast leads capped (for multi-tap).
4. Connect the supply ground and housing ground leads to the GREEN ground screw on the mounting hood.
5. Fold all excess supply leads and fasten them into the mounting hood with the wire tie (supplied).
6. Swing the ballast housing up and tighten securely with the hex latch screw.
7. Install the lamp and tighten securely. Verify that the ANSI code of the ballast matches the installed lamp.
8. Install the globe or refractor and optional reector and/or guard per the xture label in the ballast housing. Make sure to hand-
tighten the globe or refractor into the luminaire housing. After the globe or refractor contacts the gasket surface, tighten 1/4 to 1/2
turn with a strap wrench.
Optional Smart Hot Restrike
For 50 W–150 W HPS Only:
Luminaires may be equipped with a Smart Hot Restrike (designated by a -SR sufx), which will interrupt power to the lamp at the end
of the lamp life. Smart Hot Restrike is a one-piece unit.
If the lamp does not start within 1–2 minutes of initial power application to the luminaire, the starter will open the secondary side of the
circuit and will disconnect the power to the lamp. The starter can be reset by interrupting the main power supply to the luminaire for
several seconds.
CAP
277
CAP
240
208
COM
120
COMMON
HSP MT (HX-HPF)
Appleton • 1.800.621.1506 • www.appletonelec.com
LAMP LEAD
SMART HOT
RESTRIKE
COMMON
LAMP
BLACK
HV LEAD
WHITE
650135-005 Rev. K 07/13 • Page 4 of 8
Wiring Diagrams
DUAL-TAP
SUPPLY
CONNECTION
277
LAMP
277
COM
120
COM COM
HPS DT (HX-HPF)
480
LAMP
CAP
COM COM
HPS 480V (CWA)
CAP
277
CAP
120
COM
240
208
120
BLACK
BLACK
COM
GREEN GROUND TO
MOUNTING HOOD
BLACK LINE TO
PROPER VOLTAGE TAP
WHITE SUPPLY LINE
TO COMMON
WIRE CONNECTOR
BLACK
X1
X3
IGN
X2
WHITE
WIRE CONNECTOR
BLACK
X1
X3
IGN
X2
WHITE
WIRE CONNECTOR
LAMP
COM
IGN
X2
BLUE
SWITCH
BLACK
WHITE
BLUE
277
120
COMMON
CAP
277
240
COM
208
120
COM COM
HPS MT (HX-HPF)
480
CAP
COM
COM
BLACK
BLACK
HPS 480V (CWA) QTZ
277
240
208
120
COM
CAP
COM
BLACK
MULTI-TAP
SUPPLY
CONNECTION
WIRE CONNECTOR
LAMP
LAMP
BLACK
X1
X3
X2
WIRE CONNECTOR
X1
X3
X2
BLUE
SWITCH
WIRE CONNECTOR
LAMP
X3
BLACK
IGN
WHITE
IGN
X1
X2
BLUE
SWITCH
BLACK
BLUE
BLACK
IGN
WHITE
WHITE
BLUE
GREEN GROUND TO
MOUNTING HOOD
BLACK LINE TO
PROPER VOLTAGE TAP
WHITE SUPPLY LINE
TO COMMON
CAP
LAMP
480
X3
COM
COM COM
HPS 480V (HX-HPF)
277
240
208
120
COM COM
LAMP
X3
CAP
HPS MT (CWA)
PSMH MT (SUPER CWA)
277
240
208
120
COM
WIRE CONNECTOR
CAP
COM
COMMON
WIRE CONNECTOR
BLACK
X1
IGN
X2
WHITE
WIRE CONNECTOR
BLACK
X1
IGN
X2
WHITE
BLACK
WHITE
277
240
208
120
HPS MT (CWA) W/QTZ
HPS MT (HX-HPF) QTZ
120
COM
WIRE CONNECTOR
277
240
208
120
COM
BLACK
COM
CAP
BLACK
WHITE
BLUE
BLACK
SWITCH
PSMH MT W/QTZ
BLUE
PSMH MT (SUPER CWA) W/QTZ
COM
BLACK
CAP
BLACK
WHITE
BLUE
WIRE CONNECTOR
BLUE
SWITCH
480
120
COM
BLACK
PSMH 480V W/QTZ
Appleton • 1.800.621.1506 • www.appletonelec.com 650135-005 Rev. K 07/13 • Page 5 of 8
PSMH MULTI-TAP
WIRE CONNECTOR
480
COM
CAP
COM
PSMH MULTI-TAP
BLACK
WHITE
Mercmaster III Family Tree & Parts List
Flexible Pendant Mount
KPAF75
KPAF100
POLYMERIC
REFRACTORS
NEMA 2 LPRF-2CP
NEMA 3 LPRF-3CP
NEMA 4 LPRF-4CP
NEMA 5 LPRF-5CP
• Fluorescent
• Metal Halide
100W Max.
(Lamp Extender
not required)
Standard Dome
KR2-ST
HID GLASS GLOBE
Clear VPGL-1HR
5-5/8"
Pendant Mount
KPA100
MLBG SERIES
35W-150W HPS
50W-175W PSMH
Med. Base
5-1/2"
26-84W Fluorescent
(Section F3)
30° Angle
KR2-AN
8"
KPA75
Standard Dome
CMR-4ST*
GLASS GLOBE
Clear VPGL-3HR
GLASS GLOBE
Fluorescent
Clear VPGL-2HR
Pendant Cone Mount
KPCH75
KPCH100
MLBR SERIES
35W-150W HPS
50W-175W PSMH
Med. Base
7-3/4"
26-84W Fluorescent
(Section F3)
30° Angle
CMR-4AN
GLASS REFRACTORS
NEMA 1 LPG-R1
NEMA 3 LPG-R3
NEMA 5 LPG-R5
KRG2
Refractor Guard
Ceiling Mount
KPC75
KPC100
KPB SERIES
50W-150W HPS
100W-200W PSMH
Mogul Base
5-1/2"
Metal Halide
100W Max
Lamp Extender
POLYMERIC
REFRACTORS
NEMA 2 LPRF-2CP
NEMA 3 LPRF-3CP
NEMA 4 LPRF-4CP
NEMA 5 LPRF-5CP
KGU1
HID Globe
Guard
6-3/4"
9.25"
EXIT
Three-Way Exit Sign
CJEXRN
Appleton • 1.800.621.1506 • www.appletonelec.com
8-1/2"
5-3/4"
KGU2
Fluorescent
Globe Guard
DIA.
13-1/4"
6-5/8"
5-11/16"
11-3/8"
Standard Dome
KR2-ST
30° Angle
KR2-AN
GLASS GLOBES
Clear VPGL-2HR
KGU2
Globe Guard
650135-005 Rev. K 07/13 • Page 6 of 8
Mercmaster III Family Tree & Parts List
25° Stanchion Mount
KPS125
KPS150
KPBR SERIES
50W-150W HPS
100W-200W PSMH
Mogul Base
90° Stanchion Mount
KPST125
KPST150
Wall Mount
KPS125
KPS150
KPB SERIES
250W-400W HPS
250W, 320W,
350W, 400W PSMH
Mogul Base
KPR-4HB
16” Lens Enclosed
Reector
GLASS GLOBE
Clear VPGL-3HR
Appleton • 1.800.621.1506 • www.appletonelec.com 650135-005 Rev. K 07/13 • Page 7 of 8
Except as expressly provided by Appleton Electric, LLC (Appleton), Appleton products are intended for ultimate purchase by industrial users and for operation by persons trained and experienced in the use and maintenance of this equipment
and not for consumers or consumer use. Appleton warranties DO NOT extend to, and no reseller is authorized to extend Appleton’s warranties to any consumer.
While every precaution has been taken to ensure accuracy and completeness in this manual, EGS Electrical Group, LLC. assumes no responsibility, and disclaims all liability for damages resulting from use of this information or for any errors
or omissions. Specications are subject to change without notice. The Appleton and Emerson logos are registered in the U.S. Patent and Trademark Ofce. All other product or service names are the property of their registered owners.
©2013 EGS Electrical Group, LLC. All rights reserved.
650135-005 Rev. K 07/13 • Page 8 of 8
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