Model 450-R Single LED Versa Light Retrofit Install Procedure
120-240 VAC
HALOGEN TO LED RETROFIT TO BE PERFORMED BY
QUALIFIED SERVICE PERSONNEL ONLY
INSTALLATION OF EQUIPMENT LISTED IN THIS MANUAL REQUIRES ABILITY EQUIVALENT TO
THAT OF A LICENSED ELECTRICAL TRADESMAN
IMPORTANT
These instructions should be used only for Versa Light Models 420, 420A, 420B,
421, 421X, 421B, 421BX, 470, 470B, 471, 420X, 420AX, 420BX. For any questions
regarding if upgrade kit is compatible with Versa Light then please contact DL
Customer Service at 315-463-7348.
The Versa Light being retrofitted must be in working order prior to Installing the
Retrofit Components. The Fan and Halogen light must be in working order.
Electrical Connections are to be modified on the Secondary of the Transformer
only. Do not rewire any of the Black or White wires connected to the Transformer
Primary.
INTRODUCTION
This Retrofit Procedure describes how to replace the Halogen Bulb which operates from
18 VAC with an LED Head Assembly that operates from a Constant DC Current of .7A
at approximately 42 VDC.
When powering the Halogen Bulb, two parallel connected Transformer Secondary’s
provide the power. When powering the LED Head Assembly, the Transformer
Secondary’s are reconnected in series and attached to a Printed Circuit Board mounted
on top of the Transformer which serves as an AC to DC convertor. This PC Board
protects the LED Head Assembly from being connected in reverse polarity and provides
a Constant DC Current to Drive the LED in the Head Assembly. The Fan must Operate
in order to cool the Heat Sink in the LED Head Assembly. If the Fan is off, the LED
Head Assembly will cycle On and Off by the Thermostat attached to the Heat Sink.
VL9151 Rev B 8/27/2010 Page 1 of 7
Model 450-R Single LED Versa Light Retrofit Install Procedure
120-240 VAC
Tools needed: Electrical Multi Meter, Phillips screw driver, Pliers, Needle nose pliers
Step 1. Verify Voltage is 120-240 VAC for existing light
Step 2. Unplug Light
Step 3. Remove Versa Light from mounting location and place on flat surface
Step 4. Remove bulb, bulb spring and socket
A. Remove bulb from light by pulling bulb spring out of shield groove.
B. Disconnect bulb socket from the tube harness at the Bullet Connectors.
Step 5. Remove old flex tube from cabinet
A. Straighten the tube. Pull on tube while unscrewing counter clockwise from
cabinet. If the flex tube does not come out after 12 turns, put a small screw
driver between tube and cabinet to keep tube spring from rotating with the
tube. Discard the bulb, bulb spring, bulb socket and flex tube assembly.
Remove tube spring with small screwdriver.
B. Straighten the bulb wire harness and measure from the top of the Versa
light box to the bullet connectors. If it less than 39in, install the 3” extender
leads (see Figure #3).
Step 6. Remove light head from new tube assembly
Remove the wire form and pull the light head assembly from the aluminum
funnel using a pair of needle nose pliers. DO NOT pull on the lens, pull on
one the aluminum heat sink fins (Figure 1).
Funnel
Figure 1
Groove
LED Head
Assembly
Wire Form, bent legs
toward heat sink
Pull on fins to
remove LED
Head
VL9151 Rev B 8/27/2010 Page 2 of 7
Model 450-R Single LED Versa Light Retrofit Install Procedure
120-240 VAC
Step 7. Install new LED flex tube into cabinet
A. Install new bearing tube spring.
B. Slide new LED tube assembly over tube wire harnesses.
C. Push tube into cabinet. NOTE: If the tube does not push in with 15-20
pounds force then rotate tube and try again.
Figure 2A
Figure 2
Tabs
Bullet Connectors
DO NOT PINCH
Wire form seated
under ridge
Tube Spring
Step 8. Reattach light head to LED tube Assy.
A.
B.
C.
Plug wires from LED head into the bullet connects on the tube wire
harness. (Black to Red, Red to Red orientation not important)
While referring to Figure 1, push the heat sink into the funnels, making
sure not to pinch or cut any wires. The heat sink should be below the
ridge in the funnel Figure 2A.
Install the wire form to hold the heat sink in place, with legs toward the
heat sink. The wire form should be under the groove in the funnel.
IMPORTANT Wire Form should be positioned as shown in “Correct”
Photo Below, Not like the “Incorrect” that knocked connector P2 off the PC
Board (Lens was not shown for clarity).
CORRECT
Wire Form Legs are away
from the PC Board
Connectors
INCORRECT
Leg of Wire Form knocked
P2 off PC Board. Light will
not work!
VL9151 Rev B 8/27/2010 Page 3 of 7
Model 450-R Single LED Versa Light Retrofit Install Procedure
120-240 VAC
Step 9. Remove cover
Screw
Figure 3
Remove old label and replace
with 450-R label as shown
Cover
Remove ETL
label or cover
with supplied
sticker
Wires 39” from top of box to end
of wires, if less add extenders
Screw
Remove cover by taking out two Phillips head screws (Figure 3). Do not
remove the switch.
Step 10. Install PC Board Assembly VL8060 (Wires from H1 & H2)
Figure 4
Wire
from H4
Wire
from H3
Wire
from H2
Wire
from H1
A. Place board assembly (Figure 4) over transformer, loosen screws until
bracket sets on top of transformer then tighten screws to a maximum
torque of 8 inch pounds. (Figure 5A & 5B).
VL9151 Rev B 8/27/2010 Page 4 of 7
Model 450-R Single LED Versa Light Retrofit Install Procedure
120-240 VAC
Figures 5A & 5B
B. Unplug red wires from transformer.
C. If Versa Light XL Model, remove black thermistor on center two tabs and
wire harness see (Figure 7).
D. Plug one red wire with pink terminal into red wire from H1. Second light
blue terminal attached to red wire is not used. (Figure 6)
E. Plug the other red wire into black wire from H2. Second light blue terminal
attached to red wire is not used. (Figure 6)
Figure 6
VL9151 Rev B 8/27/2010 Page 5 of 7
Model 450-R Single LED Versa Light Retrofit Install Procedure
120-240 VAC
Step 11. Install PC Board Assembly VL8060 (Wires from H3 & H4)
A. Plug wire from H3 onto bottom right hand tab of transformer. (Figure 7)
B. Plug wire from H4 onto top right hand tab of transformer. (Figure 7)
C. Plug jumper onto tabs A & B. (Figure 7)
Figure 7
Tab B
Jumper
Tab A
Figure 8 VL8060 Installed in Cabinet
Step 12. Testing procedure
A. Plug into outlet and turn switch on. The light should turn on.
B. If light does not come on, check to see if the Red LED on the PC Board
assembly is on (see figure 6 for Red LED location).
C. If the Red LED is on, unplug light from the outlet and swap wires that are
connected to the Red and Black wires coming from the PC Board
assembly.
VL9151 Rev B 8/27/2010 Page 6 of 7
Model 450-R Single LED Versa Light Retrofit Install Procedure
120-240 VAC
D. Plug light back into outlet. The Red LED should now be off and the light
should be on.
E. Unplug light and reattach the cover with the Phillips head screws.
Step 13. Put on labels
A. Remove the label and replace with Model 450-R label (see figure 3).
B. Put a blank label over the ETL label if there (see figure 3).
Step 14. Remount light to wall
Basic Wiring Diagram for 120 VAC Power
13
VL9151 Rev B 8/27/2010 Page 7 of 7