Cooper Lighting Recalls 42,000 Metalux High Bay LED Fixtures Over Fire Hazard — What Installers and Facility Managers Need to Know

Cooper Lighting Recalls 42,000 Metalux High Bay LED Fixtures Over Fire Hazard — What Installers and Facility Managers Need to Know

Cooper Lighting Recalls 42,000 Metalux High Bay LED Fixtures Over Fire Hazard — What Installers and Facility Managers Need to Know

By Liora Light Editorial Staff · July 15, 2026

Industrial warehouse with high bay LED lighting fixtures hanging from ceiling
High bay LED fixtures are essential in warehouses and industrial facilities, but a major recall highlights the importance of product safety and proper installation. Photo: Unsplash

Table of Contents

What Happened: The Recall at a Glance

Cooper Lighting Solutions, the Peachtree City, Georgia-based commercial lighting manufacturer, has voluntarily recalled approximately 42,000 Metalux Optimized High Bay LED light fixtures. The U.S. Consumer Product Safety Commission (CPSC) published the recall notice on July 9, 2026, following a determination that the LED driver board inside the affected fixtures can overheat during normal operation, creating a fire hazard.

The recall covers fixtures sold nationwide through electrical distributors and wholesale suppliers from January 2023 through March 2026. Depending on the specific model and configuration, consumers paid between $200 and $450 per unit. The fixtures were manufactured in China and imported by Cooper Lighting LLC.

As of the recall announcement date, Cooper Lighting had not received any reports of fires or injuries related to the defect, but the company and the CPSC are urging all owners and facility managers to stop using the affected fixtures immediately and inspect their installations.

Electrician inspecting LED light fixture on a factory ceiling
An electrician performs maintenance on a high bay LED light fixture. Facilities affected by the recall should schedule inspection immediately. Photo: Unsplash

Which Models Are Affected

The recall applies to the Metalux Optimized High Bay series, which encompasses two primary model families: the OMB22 series and the OMB28 series. These are linear, suspended-mount LED fixtures designed for commercial and industrial applications with ceiling heights typically ranging from 15 to 40 feet.

The OMB22 models are 2-foot by 2-foot fixtures, while the OMB28 models measure approximately 2 feet by 4 feet. Both series were available in multiple lumen output configurations, ranging from approximately 10,000 to 40,000 lumens, and came with options for integrated sensors, emergency battery backup, and dimming capabilities. The model number and date code are printed on a label affixed to the fixture housing.

These are not residential products. They were designed for and installed in:

  • Warehouses and distribution centers
  • Manufacturing plants and factory floors
  • Big-box retail stores and wholesale clubs
  • Gymnasiums and indoor sports facilities
  • Cold storage and food processing facilities
  • Transportation and logistics hubs

Fixtures installed in facilities with high ceilings or difficult-to-access mounting locations present a particular challenge for inspection and replacement. Facility managers should consult with a licensed electrician if access requires specialized lift equipment.

Understanding the Fire Hazard

The root cause of the recall lies in the LED driver board — the internal electronic component that converts incoming AC power to the regulated DC current that LEDs require. According to the CPSC notice, the driver board in affected units can overheat beyond its rated thermal tolerance. When this happens, the board itself or surrounding components can degrade, creating conditions that could lead to smoke, charring, or in worst-case scenarios, open flame.

LED driver overheating is not a new concern in the industry, but it is unusual at this scale from a major manufacturer like Cooper Lighting Solutions, which is a subsidiary of Signify N.V., the world's largest lighting company. The thermal management of LED drivers has been a focal point of product safety testing for years, and reputable manufacturers typically build in multiple layers of thermal protection, including automatic shutoff circuits, heat sinks, and fire-resistant enclosures.

In this case, the CPSC determined that the existing safeguards were insufficient to prevent the overheating condition from occurring across the full range of operating environments the fixtures were rated for. The recall was categorized as a fire hazard — the most serious designation the CPSC assigns outside of immediate life-threatening risks.

What Owners and Facility Managers Should Do Immediately

The CPSC and Cooper Lighting have issued clear instructions for anyone who owns or manages a facility with the affected fixtures:

Step 1: Stop using the fixtures. Power down the affected lighting circuits at the breaker panel. Do not rely on wall switches or occupancy sensors alone — a full disconnect at the circuit level is the safest approach.

Step 2: Inspect and identify. Locate the product label on each fixture housing. Check the model number against the recall list. The model numbers OMB22 and OMB28 will be printed clearly on the label. If the fixture is mounted in a location that cannot be safely accessed without a scissor lift or scaffolding, schedule a professional inspection.

Step 3: Contact Cooper Lighting. The company has established a dedicated recall hotline and web portal. Owners can reach Cooper Lighting toll-free at 1-866-888-3789 or visit the recall page at cooperlighting.com/ohb-recall. The company will require the model number, date code, and proof of purchase if available, though fixtures can still be processed without the original receipt.

Step 4: Choose a remedy. Cooper Lighting is offering two options: a free replacement fixture that incorporates a redesigned driver board, or a full refund of the purchase price. For facilities with dozens or hundreds of affected fixtures, the company is coordinating bulk replacement logistics through its network of electrical distributors.

Step 5: Do not attempt a DIY repair. The CPSC explicitly warns against attempting to repair or modify the driver board. The thermal issue is inherent to the component design and cannot be corrected through field servicing.

The Scale of the Recall and Where Fixtures Were Sold

At approximately 42,000 units, this is one of the larger lighting fixture recalls in recent years. For context, the typical commercial lighting recall involves a few thousand units. The 42,000-unit figure reflects the Metalux Optimized High Bay's position as a volume seller in the commercial contractor channel.

The fixtures were sold through Cooper Lighting's extensive distribution network, which includes national electrical supply chains such as Graybar, Rexel, Sonepar, and CED Greentech, as well as regional and independent electrical wholesalers. The products were also available through online distributors serving the contractor and facilities maintenance markets.

Because electrical distributors rarely maintain end-customer purchase records for commodity commercial fixtures, tracking down every installed unit will be a significant challenge. Cooper Lighting is relying on the CPSC recall announcement, trade media coverage, and direct outreach through its distributor partners to reach affected customers.

Industry Context: LED Driver Safety in High Bay Applications

High bay LED fixtures operate in demanding thermal environments. Unlike residential downlights or office troffers, high bay fixtures in warehouses and factories are frequently exposed to ambient temperatures that can exceed 100 degrees Fahrenheit near the ceiling, especially in unconditioned spaces during summer months. The driver board must reliably dissipate its own internally generated heat on top of the ambient load.

Industry engineers refer to this as the "thermal stack-up" problem: ambient heat plus self-generated heat plus any insulation or enclosure effects can push component temperatures past their rated maximum. The issue is well understood in the lighting industry, and testing standards from organizations like UL Solutions and the DesignLights Consortium (DLC) include thermal endurance requirements specifically designed to catch these failure modes.

The fact that 42,000 units reached the market with a driver board susceptible to overheating suggests a gap in either the accelerated life testing protocols used during product development or the quality control procedures applied during manufacturing. In either case, the recall is likely to prompt competitor manufacturers to re-examine their own driver board sourcing and thermal testing procedures.

For lighting specifiers and electrical contractors, the recall underscores the importance of verifying that any high bay LED fixture specified for a project carries current UL or ETL certification and, where applicable, DLC qualification. These certifications are not guarantees against defects, but they establish a baseline of independent safety testing that reduces the probability of field failures.

Modern warehouse interior with LED high bay lighting illuminating aisles
LED high bay fixtures remain the most energy-efficient choice for warehouse illumination, but the recall highlights the importance of choosing certified, thermally tested products. Photo: Unsplash

Cooper Lighting's Response and Remedy Program

Cooper Lighting has set up a dedicated recall resource page at cooperlighting.com/ohb-recall, where facility managers can find detailed identification guides, contact information, and the replacement request form. The company is also coordinating with its distributor network to ensure that replacement inventory reaches affected customers as quickly as possible.

In a statement published through the CPSC, Cooper Lighting emphasized that no injuries or fires had been reported as of the recall announcement date. The voluntary nature of the recall — initiated by the company in cooperation with the CPSC rather than mandated after an incident — is consistent with standard industry practice for proactive safety management.

For customers who need to maintain lighting in operational facilities during the replacement process, Cooper Lighting recommends implementing a temporary lighting plan. Options include portable LED floodlights, reduced-density operation of unaffected fixtures, or accelerated replacement scheduling during planned maintenance shutdowns. The company notes that replacements will be prioritized for facilities where lighting is critical for safety, such as 24-hour manufacturing operations and cold storage facilities where darkness poses a slip-and-fall risk.

Broader Implications for Commercial Lighting Buyers

The Metalux recall arrives at a time when the commercial LED lighting market is undergoing significant consolidation and cost pressure. As manufacturers compete on price for high-volume commercial fixtures, the margin for safety-related overengineering can shrink. This recall may accelerate a shift among institutional buyers — school districts, municipal facilities, federal agencies — toward procurement policies that weight third-party safety certifications and manufacturer track records more heavily than upfront fixture cost.

For homeowners and residential buyers, the recall serves as an indirect reminder that quality and safety testing matter, even if the affected product category is commercial rather than residential. The same principles of driver board design, thermal management, and safety certification apply to the LED fixtures found in residential kitchens, living rooms, and home offices. When evaluating any LED fixture — whether a warehouse high bay or a decorative chandelier — the presence of UL or ETL listing is the minimum threshold buyers should look for.

At Liora Light, every fixture in our collection undergoes rigorous safety testing and carries the appropriate certifications. We believe that transparency about safety standards and component sourcing should be the norm in lighting retail, not the exception.

Conclusion

The Cooper Lighting Metalux Optimized High Bay recall is a significant event in the commercial lighting industry, affecting tens of thousands of fixtures across warehouses, factories, and retail facilities throughout the United States. While no injuries or fires have been reported, the CPSC's classification of the defect as a fire hazard warrants immediate attention from every facility manager and electrical contractor with these fixtures in their portfolio.

Owners should power down affected circuits, inspect fixtures for the OMB22 or OMB28 model designation, and contact Cooper Lighting to arrange a free replacement or refund. The company's proactive approach — issuing a voluntary recall before any fire or injury incident — reflects responsible product stewardship, even as the underlying driver defect raises questions about thermal testing protocols.

For the broader lighting industry, the recall is a reminder that the transition to LED technology, while overwhelmingly positive in terms of energy efficiency and longevity, has not eliminated the fundamental engineering challenges of thermal management and component reliability. Safety remains the first requirement of any lighting product, commercial or residential.

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