GE DG6, DG5, FG5, FG6, LM5 Installation Guide
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GE
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Lighting Solutions
Industrial Luminaires with Electro-
Mechanical Sliding Optical Disconnect
Installation and Maintenance
VERSABEAM PROTECTED BY
U.S. PATENT NUMBER 5,416,684
FG5, FG6 DG5, DG6 OG5, OG6 LM5 VS5
MOUNTING
READ THOROUGHLY BEFORE INSTALLING
Save instructions for future use.
Conduit Mounting:
GEH-5864C
INSTRUCTIONS
FG6
LARGE BALLAST HOUSING FOR
SOME OPTIONS
(See GE Lighting Systems Product
Catalog for details)
WARNING
Risk of electric shock
• Turn power off before servicing
– see instructions
NOTE: Maximum fixture ambient temperature rating is determined by the lesser rating as
indicated on the ballast assembly and the optical assembly.
GENERAL
This luminaire is designed for indoor (check label for damp or wet location suitability) applications, and
should be installed and maintained according to following recommendations. It consists of two assemblies, ballast and optical, which may be shipped separately.
Any part damaged or broken during or after assembly should be replaced.
If the luminaire you ordered has a polycarbonate or acrylic refractor, please pay particular attention
to the following statement:
All polycarbonates, acrylics and articles made from polycarbonates or acrylics will yellow with time.
The rate of yellowing is determined by the specific material, any additives and coatings, as well as the
optical temperature and exposure to ultraviolet (UV) light.
This yellowing can reduce the light output and impact resistance of products made from polycarbonates or acrylics. In no case should the maximum wattage recommendations listed for the luminaire be
exceeded. Contact factory for more information.
UNPACKING
This luminaire has been properly packed so that no parts should have been damaged during transit.
Inspect to confirm.
No damaged parts should be installed.
NOTE: The luminaire is supplied with a mounting plate or a hanger hub and locking nut which are
threaded together, which is included in carton with the ballast housing.
INSTALLATION
WARNING
Risk of fire
• Keep combustible materials away from lens
– see instructions
• Use lamps specified on nameplate
1. Fasten mounting plate (minimum of five full turns) to 3/4-inch conduit by threading the mounting plate
onto conduit. (Figure 1)
2. Tighten set screw to lock mounting plate to conduit.
3. Loosen set screw on the top corner of the ballast housing.
4. Loosen wiring box door screws on the ballast housing to allow the wiring box door to pivot.
5. Pivot the wiring box door 180 degrees to allow the mounting plate room to slide onto the ballast
housing.
6. Slide mounting plate onto ballast housing, making sure that the upper rim of the ballast housing slides
into the rails of the mounting plate. (Figure 2)
7. Tighten the set screw on the top corner of the ballast housing so that the mounting plate cannot back
out.
8. After wiring is complete, pivot the wiring box door back into the original position and tighten the two
wiring box door screws.
Figure 1
CAUTION
Unit will fall if not installed properly
• Follow installation instructions
NOTE: Minimum clearance of 3 feet must be maintained below luminaire.
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or
maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred
to GE Lighting Solutions.
Flexible Mounting: If flexible mounting accessories (hook or loop) are supplied separately, thread
shaft into mounting plate and follow instructions above for conduit mounting.
CAUTION: If this instruction is not followed damage to the mounting parts can occur causing the
fixture to fall. When using hook or loop fixture mounting, do not apply luminaire weight when the
mating parts are as shown in Fig. A. Do not apply any twisting action to the hook and loop assembly.
When properly installed the hook and loop assembly is shown in Fig. B.
Figure 2
Additional Instructions for Wet Location option (provide
water tight seal between conduit and hanger hub)
1. Fasten hanger hub securely (minimum of five full turns) to
3/4-inch conduit by threading locking nut and hanger hub
assembly onto conduit. (Figure 3)
2. Orient any one of arrows on bottom of hanger hub in
direction that you wish a flat side of ballast housing to
face.
3. Tighten set screw to lock hanger hub to conduit.
4. Loosen locking nut until free to move up conduit.
5. Twist supply leads. Slip ballast housing onto hanger hub
and position housing approximately
30 degrees counter-clockwise from final desired position.
6. Rotate housing clockwise until seated on hanger hub with
wiring box facing in desired direction.
NOTE: Check for proper seating by trying to rotate assembly counter-clockwise while it is supported by the
hanger hub.
7. Hand tighten locking nut against ballast housing. When
installing units provided with a gasket between hangerhub and locking nut, be sure to tighten nut securely so
that gasket is compressed fully around pipe nipple to
prevent entrance of moisture.
Schéma A
Schéma B
2. Refer to LAMP INSTALLATION and screw lamp into socket.
Locking
Tabs
Socket
Locking
Tabs
Socket
Quartz
Socket
Figure 4 Figure 5 Figure 6
NOTE: In case of unit LM5, lamp installation is accomplished through access door in lens by using a
relamp stick.
3. (For enclosed units only) Close door and secure properly in place by latching first latch opposite hinge,
followed by other latches.
NOTE: The OG5 has wing nuts in place of latches.
LAMP INSTALLATION/REPLACEMENT
CAUTION
Risk of burn
• Allow lamp/fixture to cool before handling
Figure 3
WIRING
Make all electrical connections in accordance with the National Electrical Code and any applicable
local code requirements.
Verify that supply voltage is correct by comparing it to nameplate.
If unit is designated as multivolt or multiwatt, follow specific instruction.
Single Voltage Units: Installer needs to connect supply conductors to primary leads and fixture
ground wire. These wires are located on the small wiring harness that contains the 9-pin plug. After these
wires are connected, the 9-pin plug wired in the fixture needs to be mated with the 9-pin plug wired to the
supply conductors (assuming that they are not already connected).
Multi-Volt Units: (Connectable for 120, 208, 240 & 277 volts)
CAUTION: DO NOT REMOVE INSULATED CONNECTORS FROM WIRES NOT NEEDED FOR REQUIRED
VOLTAGE CONNECTION.
Select proper wires from connection diagram on unit. Connect specified wires by utilizing crimp
connectors on wires. These crimp connectors are sized for 14-16 AWG. For other AWG sizes remove crimp
connector(s) provided and use other appropriate approved connector(s).
Multi-Watt Units: See procedure under Multi-Volt above.
NOTE: Attach ground conductor to the green ground wire supplied with the fixture.
9-PIN PLUG REMOVAL: Removal of the 9-pin plug does not hinder the electrical performance of the
luminaire, but its removal does negate the GELS diagnostics meter compatibility.
FINAL ASSEMBLY
LIGHT DISTRIBUTION ADJUSTMENT: FG5, FG6, DG5, DG6,OG5, OG6
The optical assembly is provided with an adjustable socket holder for changing spacing criteria.
Position is preset at factory to meet specified spacing criteria. If it is necessary to adjust socket, consult
photometric tables given in the catalog. Loosen clip screws to allow socket holder to rotate freely. Desired
position is selected by aligning step designation with clips. Rotate clips back to their original position and
retighten screws.
OPTICAL ASSEMBLY/MOUNTING
FG5, FG6, DG5, DG6, LM5, OG5, OG6, VS5
NOTE: Dustproof/weatherproof and severe-duty units are provided with a sponge rubber gasket (in bag
attached to ballast housing) that should be slipped over electrical plug prongs of optical assembly
before final assembly.
1. (Figure 4) Secure reflector to bottom of ballast housing. Installation is aided by key hole slots in
reflector. On VS5 units with safety chains, orient the reflector so that the ballast and reflector holes
are on the same side.
1a. On VS5 units push the reflector mounting bracket thru the reflector opening and slide it over the socket
brackets all the way. On 400 watt Metal Halide units the top (first) hole of the mounting bracket will
snap over the socket bracket screws. On all others, the bottom (second) hole will snap over the
bracket screws. (Figure 5) For additional assembly instructions, refer to the instruction sheet that
came in the small box with the metal reflector and mounting bracket.
NOTE: If VS5 unit has a safety light option, clip quartz socket over socket bracket leg and reflector
bracket leg in a horizontal position (see Figure 6).
The light output of a luminaire is dependent on the age of the lamp. In applications where light level
is critical it may be desirable to replace lamps before they burn out. Lamp manufacturer can provide data
showing how lamp light output decreases with use.
Use only lamps specified on nameplate. Observe lamp manufacturer’s recommendations and
restrictions on lamp operation, particularly ballast type, burning position, etc.
BODY TIGHTNESS: The lamp should be securely inserted and tightened to NEMA-EEI specified torque
of 35 inch-pounds, which is best achieved by firmly tightening to insure application of sufficient torque.
Tightening must be sufficient to fully load and depress the load center contact of socket.
If unit has a SAFETY LIGHT option, insert quartz lamp in its socket making sure to wipe any fingerprints
off lamp.
NOTE: Use of lubricants on lamp bases or sockets can cause rapid lamp failure and voids your fixture
warranty.
SAFETY CHAINS
CAUTION: When used, safety chains must be carefully installed as outlined below.
Safety chains may be attached to luminaire when user feels safety chains should be used. Safety
chains should be attached in a manner to give minimum slack. In no case should a ballast or optical safety
chain be installed in a manner which permits luminaire to fall more than six (6) inches before it is caught
by chain. To install ballast safety chain, insert “S’’ hook through hole in housing and crimp shut. Safety
chains and attachment accessories are available from factory as an optional accessory for both ballast
and optical assemblies.
To install optical safety chain, insert “S” hook through a link in ballast safety chain and crimp shut. Use
snap hook to attach to clip or hole on optical. See figure 7.
CRIMP “S” HOOK TO
LINK IN BALLAST
SAFETY CHAIN
OPTICAL SAFETY CHAIN
Figure 7
HOLE IN HOUSING
BALLAST SAFETY CHAIN
ATTACH SNAP HOOK
TO CLIP OR HOLE
ON OPTICAL
MAINTENANCE
It will occasionally be necessary to clean outside of refractor to maintain light level. Frequency of
cleaning will depend on ambient dirt level and minimum light level which is acceptable to user. Lens door
(if enclosed) should be washed in a solution of warm water and any mild, non-abrasive household detergent,
rinsed with clean water and wiped dry. Should optical assembly become dirty on inside, wipe reflector and
clean lens door in above manner, and replace any damaged gasket.
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