In this guide, I will take you step by step on how to install an electrical system in your warehouse lighting while on a budget. Even though you may not be a professional electrician, by following safety standards and seeking professional advice when in doubt, you can complete this work independently. Let’s get started!

Materials and Tools Required

First, here are the materials and tools you will need:

• A 125-ampere main lug panel
• Various RX cables, including 14/2 and 12/2
• Single, double, and quad outlet boxes
• Nails and clamps for securing wires
• Several circuit breakers

The core of your installation is a 125-amp main lug panel, which means there is no main breaker; you will control the power through circuit breakers on another panel.

Laying the Main Cable

Next, you will lay the main power cable. You are using type 63 direct burial cable, which was buried underground using a trencher when you were laying the water pipes for the warehouse lighting. The cable has two black wires and one neutral wire with a yellow stripe. Connect these cables to the new distribution panel.

Panel Installation

During the panel installation, you need to thread the cables through the pre-drilled circular holes, known as knockouts, using cable insulators to protect the connections. After connecting the main power cable, the next step is to install the outlet boxes. You will plan the placement of the outlets within the warehouse and then install the outlet boxes and wiring.

Grounding

Once the distribution panel and outlet boxes are installed, proceed with the grounding. Since this is a sub-panel, you need to add a separate ground bar, connecting it to the ground rod with bare copper wire to ensure safety.

Wiring and Circuits

It is possible to complete the wiring for one circuit at a time. First, layout the wires for outlets and light fixtures for each area of the warehouse, then connect them back to the distribution panel. Yellow RX indicates 12/2 wiring for 20-amp circuits, while white indicates 14/2 for 15-amp circuits.

You should first complete the 20-amp circuit, which will power the outlets and light fixtures at the front of the warehouse. Then, install two 15-amp circuits, one for each side of the warehouse.

Lighting Installation

Next is the lighting installation. Choose 60W LED Canopy Lights to illuminate your warehouse. These lights are very bright and only require a few units to sufficiently light up the area. JC-LGL Lighting's LED Canopy Lights are well-suited for indoor environments like warehouses. They are energy-efficient, durable, and come with corrosion-resistant die-cast aluminum casings and non-yellowing PC covers. They offer excellent waterproofing, have a rapid heat dissipation feature, and a lifespan of 50,000 hours. They can operate in temperatures ranging from -13°F to 113°F. With 5000K and a 180° beam angle, LED Canopy Lights provide higher light transmittance, lower maintenance costs, and a larger illumination area.

Before installing these led canopy lights, choose the appropriate installation spots. Due to the wide beam angle of these led canopy light fixtures, you can distribute them evenly across the warehouse ceiling or beams, ensuring no significant shadow areas are left. For optimal lighting, it is recommended to install the led canopy light fixtures centrally on the ceiling or close to work areas.

• When installing the led canopy lights, first drill holes in the ceiling or beams and then secure the brackets with screws. Ensure the installation points are sturdy to prevent the fixtures from falling. For heavier led canopy lights, use expansion bolts or similar reinforcing materials to enhance stability.
• Once the brackets are in place, connect the led canopy light fixtures' power cables to the pre-laid wires. Ensure the connections are correct, typically involving a live wire (black or red), a neutral wire (white), and a ground wire (green or bare). Secure the connections with wire nuts or junction boxes and seal them with electrical tape for safety.
• After wiring, adjust the angle of the led canopy lights if needed. If you need to focus the led light on a specific area, slightly tilt the led canopy light fixtures. To achieve uniform light distribution across the entire space, keep the led canopy lights vertically downward.
• Install protective covers and safety accessories to ensure the led canopy lights are protected from dust and moisture, especially in damp or dusty environments. Some led canopy light fixtures also come with safety wires to ensure that even if the hooks fail, the fixtures will not fall. Attach the safety wires to reinforced parts of the ceiling or beams for added security.

Circuit Testing and Project Summary

After completing all wiring and led canopy light fixture installations, conduct a power test to ensure everything is working correctly. If any led canopy light fixtures do not light up or flicker, check if the connections are secure or if there is any circuit overload. Once everything is confirmed to be in order, the led canopy lights should provide adequate and even lighting throughout the warehouse.

The total budget for this warehouse lighting project is approximately $800, with $450 allocated for electrical components and materials (such as the distribution panel, circuit breakers, and wires), and another $350 for the led canopy light fixtures.

Through this budget DIY warehouse lighting electrical installation project, you've learned how to complete power distribution and warehouse lighting systems within budget. This includes laying power lines, installing outlets, and choosing energy-efficient LED light fixtures. If you have similar DIY Lighting projects, remember to seek professional guidance and ensure all safety standards are followed.

Thank you for reading! If you have any questions, feel free to leave a comment below or contact JC-LGL Lighting’s customer service for assistance.