Installation Guide
SIGN168 | GE2031-4480

Tetra ® PowerMAX / Snap SS
LED Lighting System

GEPM2471-W1
GEPM2465-W1
GEPM2457-W1
GEPM2450-W1
GEPM2441-W1
GEPM2432-W1| GEPMH2471-W1CS1
GEPMH2465-W1CS1
GEPMH2457-W1CS1
GEPMH2450-W1CS1
GEPMH2441-W1CS1
GEPMH2432-W1CS1| GEPMH2471-W1X
GEPMH2465-W1X
GEPMH2457-W1X
GEPMH2450-W1X
GEPMH2441-W1X
GEPMH2432-W1X| GEPMH2471-W1B
---|---|---|---

BEFORE YOU BEGIN
Read these instructions completely and carefully.

For the latest North American install guides for your product go to: https://products.gecurrent.com/sign-lighting/tetra-powermax
For the latest European install guides for your product go to: https://products.gecurrent.com/eu

Prepare Electrical Wiring FOR UL ONLY
Electrical Requirements

• Acceptable for use in dry, damp, and wet locations.
• The grounding and bonding of the LED Driver shall be done in accordance with National Electric Code (NEC) Article 600.
• Follow all National Electric Codes (NEC) and local codes.
• These products are only suitable for connection to a circuit from a Class 2 power source.
• These products have not been evaluated for use when connected to a power source that does not comply with Class 2 voltage and energy limited supplies.

Save These Instructions
Use only in the manner intended by the manufacturer. If you have any questions, contact the manufacturer.

RETROFIT SIGN CONVERSION LED KIT FOR USE ONLY IN
ACCORDANCE WITH KIT INSTRUCTIONS.
KIT IS COMPLETE ONLY WHEN ALL PARTS REQUIRED BY THE INSTRUCTIONS ARE PRESENT.

WARNING

RISK OF ELECTRIC SHOCK

• Turn the power off before inspection, installation, or removal.
• Properly ground power supply enclosure.

RISK OF FIRE

• Use only suitably approved wire for input/output connections. Minimum size 18 AWG (0.82mm2 )
• Follow all local codes.
• Not to be submerged or used in a marine environment.

UL WARNING

RISK OF FIRE OR ELECTRIC SHOCK

• LED Retrofit Kit installation requires knowledge of sign electrical systems. If not qualified, do not attempt installation. Contact a qualified electrician.
• Install this kit only in host signs that have been identified in the installation instructions and where the input rating of the retrofit kit does not exceed the input rating of the sign.
• Installation of this LED retrofit kit may involve drilling or punching holes into the structure of the sign. Check for enclosed wiring and components to avoid damage to wiring and electrical parts.
• Do not make or alter any open holes in an enclosure of wiring or electrical components during kit installation.

Components

1. UL approved 18 AWG (0.82 mm 2 ) supply wire
2. UL approved 22-14 AWG (0.33-2.08 mm2 ) wire connectors or 22-18 AWG (0.33-0.82 mm 2 ) in-line/IDC connectors

3. 6 (M3) screws, 1/8 inch (3.2 mm) rivets, or electrical grade RTV silicone or equivalent

4. Weather box GEXNWB2 (optional)
5. 24 Volt Power Supply
6. Tetra® PowerMAX / Snap SS LED modules
7. Electrical grade RTV silicone:
   • Momentive RTV 6700 Series Silicone Rubber Adhesive Sealant
   • Momentive White Blanc RTV 162 Silicone Rubber Adhesive Sealant-Electrical Grade
   • Dow Corning 3140 – Non-Corrosive Flowable (clear)
   • Dow Corning 3145 – Non-Corrosive Nonflowable (clear or gray)
   • Dow Corning RTV 748 Non-Corrosive Sealant-White

Tips

• For optimal light uniformity in halo-lit applications the Tetra ® LED modules should be mounted on UL recognized plastic and the light output from the Tetra ® LED system should be directed back into the sign enclosure. This will allow for uniform backlighting of the sign and will provide simple mounting for the Tetra ® LED system.
• A best practice for the supply wire at the point at which it is brought into the sign is to have a drip loop on the inside of the letter to keep water from collecting on the Tetra ® LED strip.
• These products are not required to be enclosed or protected from the weather.

Components – Tetra ® SNAP Accessories (optional)
Tetra PowerMAX is also compatible with the following Tetra SNAP Rail components.
See https://products.gecurrent.com/led-signage-lighting for further details and install instructions.

1. Tetra SNAP Rail (GEDSRL08-3)
2. Tetra Snap SS Plastic Clip (GESSPC-3)
3. Tetra Snap SS Metal Clip (GESSMC-3)
4. Tetra SNAP Frame Endcap (GEDSFE-3)
5. Tetra SNAP Socket Endcap (GEDSSE-3)
6. Tetra SNAP Dual Rail Socket Cap (GESSDR-3)
7. Tetra SNAP T-connector (GEDSTC-3)
8. Tetra SNAP Interconnector (GEDSIC-3)

Layout Modules

1. Before you begin, clean surfaces and remove all debris from the inside of the channel letter. Clean the surfaces with a 50:50 mixture of isopropyl alcohol (IPA) and water and let dry.
   

2. Measure and cut Tetra LED strip to the appropriate length for each letter. Cuts can be made between any of the modules.
   

3. Remove tape backing and stick LED modules into place. When using tape apply approximately 15 psi pressure on the module (avoid the lens dome surface) for 5 seconds,
   full bonding strength after 24 hours. Continue until you have reached the end of the strip.
   

4. Use rivets, screws, or electrical grade RTV silicone to secure at least every fifth LED module within the channel letter. Use #6 (M3) pan-headed metal screws, 1/8-inch (3.2 mm) rivets, or electrical grade RTV silicone.
   

5. Drill a 1/4-inch (6.4 mm) hole near the LED strip and grommet the hole for supply wire access.
   

6. Remove all the debris from the inside of the channel letter and replace the sign face.
   

NOTE: For halo-lit applications LED modules should be mounted on UL recognized clear acrylic or polycarbonate. The light output from the LED system should be directed back into the sign enclosure. This will allow for uniform backlighting of the sign and will provide simple mounting.

Electrical Connections

NOTE: Do not use connectors pre-filled with silicone grease/mineral base protective grease or use silicone grease to seal connections.

1. Connect LED strips using in-line (IDC) connectors or twist-on wire connectors.
   Seal all connections in wet locations with electrical grade RTV silicone.
   

2. Must cap all exposed wires with appropriate wire connectors and seal with electrical grade RTV silicone.
   Optional: Cut wires flush to the module and seal with electrical grade RTV silicone.
   

3. Run a wire from the LED power supply to the LED module and connect.
   NOTE: Must be used with Class 2 24 Volt Power Supplies.
   NOTE: Refer to Maximum Loading & Remote Mounting Specifications on page

4. 

5. Connect the red stripe wire (+) of the LED strip to the red wire (+) of the power supply. Connect the white wire (-) of the LED strip to the black or blue wire (-) of the LED power supply.
   NOTE: All electrical connections should be suitably protected from mechanical damage and the environment. Seal all connections in wet locations with electrical grade RTV silicone.
   

OPTIONAL
A Weather Box (GEXNWB2) may be used to house and seal Class 2 connections.
A) Insert wire connectors into the weather box. Fill with electrical grade silicone and close box.
B) Secure the weather box using a #6 or #8 (M2 or M3) screw.

Retrofit Instructions

FOR UL ONLY

1. (Existing Signs Only) Prior to installation, survey the site for information regarding power and accessibility inside and outside the building. Ensure that the branch circuit supplying the existing transformer or ballast will be within the voltage ratings of the new LED power supply, and have a current rating not exceeding 20A, or that permitted by applicable local, state, or country electrical codes (whichever is less).

2. (Existing Signs Only) Remove the existing lighting equipment to be replaced, such as neon tubing or fluorescent tubes; and associated transformers and ballasts. Care should be taken not to break the existing neon or fluorescent tubes.
   NOTE: Follow all federal and local regulations when disposing of neon tubing, fluorescent tubes, transformers, and ballasts.

3. (Existing Signs Only) If removal of the existing lighting equipment eliminates the disconnect switch, as required by applicable local, state, or country electrical codes; a new disconnect switch must be installed.

4. (Existing Signs Only) Repair and seal any unused openings in the electrical enclosure. Openings greater than 12.7-mm (1/2-in) diameter require a metal patch secured by screws or rivets and caulked with non-hardening caulk. Smaller openings may be sealed with non-hardening caulk.

5. (Existing Signs Only) A clean and dry mounting surface ensures optimum adhesion if the self-adhesive method of mounting is chosen. Follow the manufacturer’s directions when using a non-oil-based solvent, such as rubbing alcohol to clean the surface area where you intend to mount the module. Before installing, ensure the surface is dry.

6. Using the layout guidelines above, determine the required number of LED modules required to illuminate the sign.

7. A 24VDC Class 2 Power Supply, as listed below, must be used with this retrofit kit. Using the Maximum Loading chart below, determine the number of Power Supplies required to power the number of LED modules required to illuminate the sign, so as not to overload the Power Supply chose.

8. Follow the instructions above to properly mount the LED modules.

9. Connect the DC output of the power supply to the LED modules using the Electrical Connections instructions above.

10. Connect the power unit to the supply in accordance with the applicable local, state, and country electrical codes, and the instructions found in the power supply installation guide.

11. If required, the disconnect switch shall be installed by qualified personnel, in accordance with applicable local, state, and country electrical codes.

Troubleshooting

Symptom

|

Solution

---|---
All letters are OFF| • Check AC input connection and/or check the circuit breaker.
• Check wire connection(s) at the Tetra® LED System and power supply for improper termination(s) or short circuits. Properly terminate or replace the wire connection(s).
• Check that connections are the red striped wire (+) of the LED strip to the red wire (+) of the power supply and the white wire (-) of the LED strip to the black or blue wire (-) of the power supply.
Some LEDs appear dim| • Ensure the overall length of the Tetra® LED System does not exceed the maximum load.
• Ensure the length of supply wire is equal to or below the recommended remote mounting distance.
• Ensure the overall length of the Tetra® LED System does not exceed the maximum load.
Some of the letters are not illuminated| • Check wire connection(s) at the Tetra® LED System and power supply for improper termination(s) or short circuits. Properly terminate or replace the wire connection(s).
• Check that connections are the red striped wire (+) of the LED strip to the red wire (+) of the power supply and the white wire (-) of the LED strip to the black or blue wire (-) of the power supply.
Shadows| • Re-route supply wire and secure to the back of the can with electrical grade RTV silicone. Adjust wire connector orientation so that it does not cover any LEDs.
• Adjust LED layout to ensure uniformity of illumination on the face of the letter.

Maximum Remote Mounting Distance from Driver Output

| 18 AWG/0.82 mm 2
Supply Wire| 16 AWG/1.31 mm 2 Supply Wire| 14 AWG/2.08 mm 2
Supply Wire| 12 AWG/3.31 mm 2
Supply Wire
---|---|---|---|---
25W Power Supply| 120 ft./36.6 m| –| –| –
80W Power Supply| 20 ft./6.1 m| 25 ft./7.6 m| 35 ft./10.6 m| 40 ft./12.1 m
100W Power Supply| 20 ft./6.1 m| 25 ft./7.6 m| 35 ft./10.6 m| 40 ft./12.1 m
180W Power Supply| 20 ft./6.1 m| 25 ft./7.6 m| 35 ft./10.6 m| 40 ft./12.1 m
200W Power Supply| 20 ft./6.1 m| 25 ft./7.6 m| 35 ft./10.6 m| 40 ft./12.1 m
300W Power Supply| 20 ft./6.1 m| 25 ft./7.6 m| 35 ft./10.6 m| 40 ft./12.1 m

Maximum Loading per 24V DC Power Supply

Power Supply| GEPM2471-W1 GEPM2465-W1 GEPM2457-W1 GEPM2450-W1 GEPM2441-W1 GEPM2432-W1| GEPMH2471-W1CS1 GEPMH2465-W1CS1 GEPMH2457-W1CS1 GEPMH2450-W1CS1 GEPMH2441-W1CS1 GEPMH2432-W1CS1| GEPMH2471-W1B| GEPMH2471-W1X GEPMH2465-W1X GEPMH2457-W1X GEPMH2450-W1X GEPMH2441-W1X GEPMH2432-W1X
---|---|---|---|---

Rating per module

| 24V DC
35mA/module 0.84W/module| 24V DC,
50mA/module 1.2W/module| 24V DC,
50mA/module 1.2W/module| 24V DC,
54mA/module 1.3W/module
GEPS24-25U-NA

Load shall not exceed 1.04A

| 25 modules/ 17 ft. (5.18 m)| 17 modules/ 34 ft. (10 m)| 17 modules/ 11.3 ft. (3.4 m)| 17 modules/

11.3 ft. (3.4 m)

GEPS24D-80U GEPS24W-80

Load shall not exceed 3.3A

| 80 modules/ 53 ft. (16.15 m)| 54 modules/ 108 ft. (33 m)| 54 modules/ 36 ft. (11 m)| 52 modules/ 34.7 ft. (10.6 m)
GEPS24-100U-GLX USVI-100024FBA USVI-100024FE

Load shall not exceed 4.0A

| ****

96 modules/ 64 ft. (19.5 m)

| ****

64 modules/ 128 ft. (39 m)

| ****

64 modules/ 42.6 ft. (13 m)

| ****

64 modules/ 42.6 ft. (13 m)

GEPS24-180U

Load shall not exceed 3.8A per each (of 2) output channels

| 90 modules/ 60 ft. (18.29 m) per bank
180 modules/ 120 ft. (36.58 m) per PS| 60 modules/ 120 ft. (36.5 m) per bank
120 modules/ 240 ft. (73 m) per PS| 60 modules/ 40 ft. (12.2 m) per bank
120 modules/ 80 ft. (24.4 m) per PS| 60 modules/ 40 ft. (12.2 m) per bank
120 modules/ 80 ft. (24.4 m) per PS
GEPS24-300U-GL

Load shall not exceed 4.0A per each (of 3) output channels

| 96 modules/ 64 ft. (19.5 m) per bank
288 modules/ 192 ft. (58.5 m) per PS| 64 modules/ 128 ft. (39 m) per bank
192 modules/
384 ft. (117 m) per PS| 64 modules/ 42.6 ft. (13 m) per bank 192 modules/ 127.8 ft. (39 m) per P| 64 modules/ 42.6 ft. (13 m) per bank 192 modules/ 128.1 ft. (39 m) per PS
GEPS24-100U-GLX2/TT

Load shall not exceed 4.0A

| 103 modules/ 68.67 ft. (20.9 m)| 72 modules/72 ft. (21.9 m)| 72 modules/ 48 ft. (14.6 m)| 66 modules/ 47.1 ft. (14.3 m)
GEPS24-200U-GLX2

Load shall not exceed 4.0A per each (of 2) output channels

| 103 modules/68.6 ft. (20.9 m) per bank 206 modules/ 137.3 ft. (41.8 m) per PS| 72 modules/ 72 ft. (21.9 m) per bank 144 modules/ 144 ft. (43.9 m) per PS| 72 modules/ 48 ft. (14.6 m) per bank 144 modules/ 96 ft. (29.2 m) per PS| 66 modules/ 47.1 ft. (14.3 m) per bank 132 modules/ 94.2 ft. (28.7 m) per PS
GEPS24-300U-GLX2

Load shall not exceed 4.0A per each (of 3) output channels

| 103 modules/ 68.6 ft. (20.9 m) per bank 309 modules/ 206 ft. (62.8 m) per PS| 72 modules/ 72 ft. (21.9 m) per bank 216 modules/ 216 ft. (65.8 m) per PS| 72 modules/ 48 ft. (14.6 m) per bank 216 modules/ 144 ft. (43.8 m) per PS| 66 modules/ 47.1 ft. (14.3 m) per bank 198 modules/ 141.4 ft. (43.1 m) per PS

This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

This Class [A] RFLD complies with the Canadian standard ICES-005. Ce DEFR de la classe [A] est conforme à la NMB-005 du Canada.

This product is intended solely for the use of non-residential signage lighting and is not intended for use in any other applications.
Conforms to the following standards:

GE Current
a Daintree Company

www.gecurrent.com
© 2021 Current Lighting Solutions, LLC. All rights reserved. GE and the GE monogram are trademarks of the
General Electric Company and are used under license. Information provided is subject to change without
notice. All values are design or typical values when measured under laboratory conditions.
SIGN168 (Rev 06/29/21) GE2031-4480

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