Wall Pack Installation Guide (Step-by-Step)

Tools, Parts & PPE

• Tools: rotary hammer (masonry), anchors appropriate for the substrate, nut drivers, torpedo level, torque screwdriver, wire strippers/crimpers, multimeter/non‑contact tester, caulk gun.
• Electrical: listed junction box, wet‑location hubs, appropriate conduit fittings, wire connectors (rated for the conductors), 0–10V low‑voltage cable (if dimming), label tape/marker.
• Controls (as required): photocell (individual or remote), motion/bi‑level sensor, time switch or network node. Verify compatibility on the spec sheet.
• PPE: safety glasses, gloves, hearing protection; fall protection for ladder/lift work; dust mask for masonry drilling.

Safety & Code Pre‑Checks

• Lockout/Tagout: De‑energize at the breaker and verify with a meter (do not rely on a single switch).
• Listing & environment: Confirm Wet Location if the fixture is outdoors. Typical safety listing is UL for luminaires; check DLC if you’re seeking rebates.
• Energy code: Certain jurisdictions (e.g., California) require photocell + occupancy/bi‑level for many outdoor luminaires. See our Title 24 outdoor lighting basics.
• Emergency egress role: If the wall pack supports egress illumination, coordinate with the life‑safety plan. For fundamentals, see UL 924 and NFPA 101.
• Electrical planning: Confirm voltage (120/277 or 347/480 V models), circuit ID, overcurrent protection, and bonding path; NEC basics: NFPA 70 (NEC) guide.

Plan Mounting Height, Layout & Neighbors

Decide why the light is there: doorway safety, perimeter walkway, loading dock, or camera support. The task determines optic, height, and lumen package. For quick lumen equivalencies and spacing, use the HID→LED sizing & spacing guide.

Need a deeper layout walkthrough? See the Wall Pack Lighting Layout & Photometric Guide for distribution (Type II/III/IV) and spacing examples.

Mount the Fixture (Brick, Stucco, Metal)

1. Prep the surface: Confirm the substrate supports the weight and wind exposure. On old brick or block, avoid edge drilling; use sleeve anchors sized for the load.
2. Backplate first: Many wall packs use a removable backplate. Set it level and dry fit the housing to confirm conduit and knockouts line up without deforming the gasket.
3. J‑box alignment: The supply conductors should enter clear of the lens and gasket. If surface conduit is used, position hubs so the top gasket area isn’t compromised.
4. Brick: Use masonry bits and dust control. Vacuum dust before installing anchors to prevent loosening over time.
5. Stucco over foam/mesh: Pre‑drill to the structural backing. Use appropriate spacers or standoffs so the housing doesn’t crush the finish.
6. Corrugated/metal building: Add a flat mounting plate behind the backplate to prevent warping and to seal ridges.
7. Torque & level: Tighten to spec, re‑check level and plumb, and confirm the gasket isn’t pinched.

Wire the Fixture (120/277 VAC, 0–10V & Controls)

Licensed electrician recommended. Follow the wiring diagram inside the housing. Typical sequence:

1. Branch conductors: Connect hot, neutral, and equipment ground with listed connectors; perform a tug‑test on each splice.
2. Driver input: Most wall packs auto‑range 120–277 VAC. If multi‑tap, confirm the correct input tap before energizing.
3. Photocell (dusk‑to‑dawn): Wire per the diagram. If false‑triggering occurs from adjacent lights, reposition or shield the cell.
4. Motion/bi‑level: For energy savings and many energy codes, add occupancy with bi‑level dim. Set a sensible vacancy level (e.g., 50–70%) that preserves camera performance.
5. 0–10V dimming: Run low‑voltage control conductors (typically purple/gray) separately from line voltage as required. Cap and isolate if not used.
6. Networked control (optional): If using nodes for remote scheduling/monitoring, follow the node manufacturer’s schematic and verify addressability before close‑up.
7. Strain relief & dressing: Dress conductors so they won’t pinch when the housing closes. Keep low‑voltage away from sharp edges.

Code note: Some jurisdictions (e.g., CA) require photocell and occupancy/bi‑level for luminaires mounted at common heights along walkways and entries. Details: Title 24 outdoor lighting basics.

Wet‑Location Sealing, Drip Loops & Cable Management

• Gaskets & lens seals: Confirm the perimeter gasket sits flat with no twists. Clean dust before closing the housing.
• Conduit entries: Use listed wet‑location hubs. Seal the top and sides with a small bead; leave the bottom unsealed to allow drainage.
• Drip loop: If conductors enter from above, create a drip loop so water falls off before the entry point.
• IP & NEMA context: For harsh exposure, review IP ratings and NEMA enclosures to match the environment.
• Corrosion control: In coastal/chemical areas, use stainless hardware where offered and apply anti‑seize; schedule periodic re‑sealing.

Aim, Commission & Set Controls

• Aiming/tilt: Start with level (zero tilt) on cutoff optics to minimize uplight and window glare. Add tilt only if you need more throw.
• House‑side shields: Add shields/visors near property lines or windows. For neighbor‑friendly strategies, see Dark Sky Friendly Wall Packs.
• Photocell: Verify day/night switching; avoid mounting under eaves that trap reflected light.
• Motion/bi‑level: Program timeouts and dim levels by area. Test a few cycles at night to make sure cameras stay effective.
• Labeling: Mark control groups and circuit IDs inside the doorframe or at the panel so future techs know the logic.

Night Testing, Documentation & Handover

1. Night walk: Look for dark pockets, scallops, and glare in doorways or on cameras. If you need to tighten uniformity, reduce spacing on the next run or step down output and add a fixture near the gap.
2. Final tweaks: Small aim changes can fix hot spots. Re‑walk after each change; don’t over‑tilt into windows.
3. Controls run‑through: Trigger photocell and motion; verify the vacancy set‑point. If your area follows Title 24, confirm required sequences.
4. Documentation: Record model/SKU, settings, and test results. File spec sheets, IES references, and label photos for closeout and future maintenance.

Layout help for next projects: When you need forward reach or tight walkway uniformity, start with the layout & photometric guide before ordering.

Maintenance & Troubleshooting

• Quarterly: Clean lenses, check seals and hardware torque, and verify photocell/motion function.
• Annually: Re‑verify dim levels and timeouts; perform a nighttime walk and adjust aiming as landscaping or camera positions change.
• Common issues & fixes:
  • Short driver life: Check thermal environment and mounting surface temperature; verify input tap and surge protection.
  • Photocell chatter: Shield from adjacent luminaires or relocate to avoid feedback.
  • False motion trips: Reduce sensitivity, adjust aim, or mask part of the sensor view.
  • Water ingress: Re‑seat the gasket, confirm hubs are tight, and maintain the unsealed drain path at the bottom.

Need rules‑of‑thumb for lumen class and spacing? Use the HID→LED sizing & spacing guide as a starting point, then verify with photometrics.

FAQ

How high should I mount a wall pack?

Most doorways land around 10–12 ft; broader coverage (loading aprons, long walks) often uses 16–20 ft. Pick the lowest height that reaches your task without creating glare, then validate with a plot at your height.

How do I wire a wall pack with a photocell and motion sensor?

Photocell handles dusk‑to‑dawn; motion triggers occupied levels. Wire each per the diagram—typically line/load for the photocell and low‑voltage or line‑voltage control for motion depending on the sensor type. Set vacancy dim (e.g., 50–70%) so cameras still perform.

Can I use 0–10V dimming?

Yes. Many models include 0–10V leads (purple/gray). Keep low‑voltage conductors separate as required, cap if unused, and ensure the control device matches the driver’s dimming range.

Do I need emergency batteries in my wall packs?

Only if they are part of the egress illumination strategy. Some projects use dedicated emergency lights instead. For life‑safety fundamentals, see UL 924 and NFPA 101.

How do I minimize neighbor complaints?

Use full‑cutoff optics, aim level, consider 3000–4000 K, add house‑side shields, and dim during off‑hours. See Dark‑Sky Friendly Wall Packs for more tips.