How to Replace Traditional High-Pressure Sodium Lamps with ZC Lighting High Mast Lights

Why Replace HPS Lamps with ZC Lighting High Mast Lights?

• 70% Energy Savings: ZC’s LED high mast lights (150W-400W) replace 400W-1000W HPS lamps, slashing electricity consumption by two-thirds. A stadium with 20 HPS lamps (1000W each) running 8 hours nightly saves over 40,000 kWh annually.
• 10x Longer Lifespan: ZC’s high mast lights last 50,000 hours (over 13 years at 10h/day) vs. HPS lamps’ 5,000-8,000 hours—eliminating frequent replacements and maintenance costs.
• Superior Illumination: 5000K-6000K cool white light (CRI ≥ 80) enhances visibility, making colors more accurate and dark areas safer. Ideal for sports stadiums (meeting FIFA/UEFA standards) and highways.
• Weather & Vibration Resistance: IP67/IP68 waterproof ratings and die-cast aluminum housing withstand extreme weather (-30°C to +50°C) and wind vibrations—critical for high mast applications (20-50 meters tall).

Pre-Replacement Planning: Assess & Prepare

1. Evaluate Existing HPS Setup

• Fixture Specifications: Record HPS lamp wattage (e.g., 400W, 1000W), mounting height (pole length), and beam angle. This helps select the right ZC replacement model.
• Pole Condition: Inspect high mast poles for rust, bending, or structural damage. ZC’s high mast lights weigh 15-30kg—ensure poles can support the weight (add 20% safety margin).
• Wiring & Controls: Check if existing wiring (voltage, gauge) is compatible with ZC’s drivers. Note if you use photocells or timers—ZC’s lights integrate seamlessly with these controls.

2. Select the Right ZC Lighting High Mast Light Model

• Sports Stadiums: ZC-ST Series (250W-400W, 37,500-60,000 lumens, 60°-90° beam angle) to meet 500-1000 lux standards for professional games.
• Highways & Airports: ZC-HW Series (150W-300W, 22,500-45,000 lumens, 120°-150° beam) for uniform coverage of large open areas.
• Industrial Yards: ZC-IND Series (200W-350W, 30,000-52,500 lumens, IP68 rating) for harsh, dusty environments.

3. Gather Tools & Safety Equipment

• High mast pole lifting system (crane or hydraulic lift for poles ≥30 meters).
• Electrical tools: Voltage tester, wire strippers, screwdrivers, and weatherproof wire nuts.
• Safety gear: Fall protection harnesses, hard hats, non-slip gloves, and safety glasses.
• Mounting hardware: ZC’s included brackets, stainless steel screws, and anti-corrosion washers.

Step-by-Step Replacement Process

Step 1: Power Off & Remove Existing HPS Fixtures

1. Shut off power to the high mast pole at the main circuit breaker. Use a voltage tester to confirm no electricity is flowing.
2. Lower the existing HPS fixture using the pole’s lifting system (never climb the pole manually for high mast applications).
3. Disconnect the HPS fixture’s wiring from the pole’s internal cables. Remove the fixture from its mounting bracket and discard it (recycle HPS lamps at a certified facility).

Step 2: Inspect & Prepare the Mounting Bracket

1. Check the existing mounting bracket on the pole for rust or damage. If worn, replace it with ZC’s universal high mast bracket (included with the fixture).
2. Clean the bracket and pole top to remove dirt, rust, or debris. Apply anti-corrosion spray to extend bracket life.
3. Ensure the bracket is level—use shims if needed to prevent the ZC fixture from tilting.

Step 3: Wire the ZC Lighting High Mast Light

1. Remove the wiring cover on the ZC fixture. Identify the color-coded wires: brown (live), blue (neutral), and green/yellow (ground).
2. Connect the fixture’s wires to the pole’s internal cables: Match brown to black (live), blue to white (neutral), and green/yellow to green (ground). Secure connections with weatherproof wire nuts.
3. Tuck the wiring into the fixture’s waterproof junction box and replace the cover—ensure it’s sealed tightly to prevent water intrusion.

Step 4: Mount the ZC Fixture & Raise It

1. Lift the ZC high mast light using the lifting system and align its mounting holes with the bracket on the pole.
2. Drive the included stainless steel screws through the fixture into the bracket, tightening until the fixture is snug (do not overtighten to avoid damaging the housing).
3. Raise the fixture to the original height (or adjust if needed for better coverage) using the pole’s lifting mechanism. Lock the lifting system in place.

Step 5: Test & Calibrate

1. Turn the power back on. The ZC fixture should light up immediately—check for flickering (a sign of loose wiring).
2. Calibrate the beam angle: For stadiums, adjust the fixture’s tilt to ensure light covers the playing surface uniformly (use a lux meter to verify 500+ lux).
3. Test controls: If using photocells or dimmers, confirm the fixture turns on/off automatically or dims as intended.

Post-Replacement Maintenance & Long-Term Benefits

• Annual Inspection: Check wiring connections, mounting stability, and lens cleanliness. Clean the lens with a soft cloth to remove dust (improves light output by 10%-15%).
• Driver Check: Every 3-5 years, inspect the LED driver for signs of overheating (e.g., discoloration). ZC’s drivers have a 5-year warranty for peace of mind.