Tetra GELW4871-1 EdgeLine Cuttable Light Bar LED Lighting System

Safety Instructions

Prepare Electrical Wiring

Electrical Requirements

• Acceptable for use in dry and damp 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.

WARNING

RISK OF ELECTRIC SHOCK

• Turn 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.

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 of 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.

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.

Components and Tools Required

1. Tetra® EdgeLine Cuttable Light Bar

2. Jumper cable with male and female connector

3. Leader cable with female connector

4. Leader cable with male connector

5. Mounting clips (88818 – standard), or (10734 – slim)

6. 10 (M5) self-tapping flathead screws

7. UL-approved 22-18 AWG (0.33-0.82 mm2) connectors or in-line/IDC connectors

8. UL approved 18 AWG (0.82 mm2) supply wire

9. 24 Volt Power Supply

10. Connector sealing cover

11. Seal Gasket and Cap

12. Electrical grade silicone.
    Examples of electrical grade silicone:

    • Momentive RTV 6702 (white) / RTV 6708 (clear) – Silicone Rubber Adhesive Sealant
    • Momentive RTV 162 (White) – Silicone Rubber Adhesive Sealant-Electrical Grade
    • Dow Corning 3140 (clear) – Non-Corrosive Flowable
    • Dow Corning 3145 (clear or gray) – Non-Corrosive Non-flowable
    • Dow Corning RTV 748 (white) – Non-Corrosive Sealant

13. Brush Conformal Coat such as the following:

    • MG Chemicals 419D
    • Humiseal 1B73, or
    • Electrolube APL

Cable Specifications

Female Connector
93155628| GE- LC24IN-66F| 24 Inch Leader Cable with IP66 Female Connector
93155627| GE-LC24IN-66M| 24 Inch Leader Cable with IP66 Male Connector

Dimensions

Planning

For planning the layout, measure the desired length to be lit and divide by the Light Bar Length (L) in the table above to determine the required quantity of light bars. If it is necessary to cut the light bar for a better fit, the cutting resolution is 3 inches (76.2 mm).

Field Cuts

WARNING

Failure to strictly follow these instructions may subject the installer or others to personal injury. Failure to strictly follow these instructions will also void the manufacturer’s warranties and may cause risk of fire, product damage, damage to property, and injury to persons. Please read all warnings contained below and follow all instructions carefully.

1. Gather materials: Seal gasket and cap, conformal coating, electrical grade silicone, sandpaper, cloth.

2. If it is necessary to cut the lightbar for a better fit, the cutting resolution is 3 inches (76.2 mm). Cut the lightbar as necessary to fit the application. Only cut the PCBA from the back to the front. DO NOT cut from the LED side to the back.
   NOTE: Perpendicular cuts ONLY. No angled cuts.

3. Clean debris from extrusion cut end with the sandpaper and avoid sanding the edge of the LED board.

4. Pull out the LED board gently and clean and deburr the cut end with a cloth or other appropriate tool. Be careful not to damage the dielectric, and to ensure no copper from the trace is making contact with the PCB assembly substrate. Finally, shake or blow out any dust and debris from the extrusion.

5. Apply and seal the cut end of the LED board with a brush-on conformal coating such as MG Chemicals 419D, Humiseal 1B73, or Electrolube APL. Allow at least 10 minutes to dry.

6. Push the GELWCAP seal gasket and cap over the cut end of the light bar.

7. Apply electrical grade RTV silicone around the outside circumference of the end cap. Ensure that the silicone completely seals the joint between the end cap and light bar.

WARNING

Field end-cap must create a water tight seal. All debris must be removed to promote a good end-cap bond and to avoid electrical failure. Use of other types of saws and/or use of a dull blade may lead to chipping or cracking of the extrusion or create a cut that cannot be sealed resulting in product failure. Product failures resulting from failure to strictly follow field cut instructions are not covered by any product warranty.

SAFETY WARNING

Failure of field end-cap to maintain a water tight seal may lead to water ingress and product failure. Product failures of this type could result in electrical shock and/or fire and damage to the product and materials which may come in contact with the product.

Attaching Light Bar Sections

Planning first:
For multiple bar installations, see the “Maximum Light Bars in Series Connection” specification in the Maximum Loading chart below. Do not exceed the maximum series length per Leader Cable.

Mounting Options A (standard or slim mounting clips)

1. Secure two mounting clips per light bar to a rigid flat mounting surface using two #10 (M5) self-tapping flathead screws along the intended run of light bar.
2. Press each light bar into its mounting clips and slide it into the adjacent light so that the alignment features in the end caps mate with each other.
   To avoid stress and damage to light bar the entire mounting surface should be flat and the mounting clips be properly aligned. If the alignment features in the end caps do not mate easily, do not force them together.
   TIP: Align light bar on one side of the mounting clips; then rotate the light bar until it snaps into other side of the mounting clips.\

Mounting Option B (standard mounting clips only)

1. Assemble the light bar by pressing two mounting clips onto the light bar. A snapping noise should be heard.
2. Mount the light bar to the desired surface using two #10 (M5) self-tapping flathead screws in each mounting bracket.
3. Mount the next light bar down the row following steps 1 and 2, being sure to align the light using the alignment features on the end cap.

Electrical Connections

1. Mate the male and female connectors of each adjacent light bar while ensuring the connectors are oriented in the same direction. DO NOT attempt to mate upside down or otherwise exert excessive force on the light bar connectors. Be sure that the retaining clip of the connectors are fully engaged and locked together as indicated by a click. Attach jumper cables as needed to work around any obstacles, corners or separations. DO NOT pull on the wires when un-mating the connectors.

2. Install an end cap into the open connector on the last light bar in the series.
   NOTE: If using leader cable with male connector (GE-LC24IN-66M), connect driver and light bar right side female connector, flip the end cap around and install it into into the open male connector on the last light bar in the series.

3. Connect the leader cable to the first light bar in the run closest to the power supply.

To Unmate Connectors

• Pushing the plug latch, grasp the connector at each end and pull apart.
• DO NOT pull on the wires when unmating the connectors.

Connect Power Supply

WARNING

RISK OF ELECTRICAL SHOCK : Turn power OFF before inspection, installation or removal.

Must be used with a Class 2, 24 Volt DC Power Supply. Grounding and bonding must be done in accordance with National Electrical Code (Article 600). Refer to the Power Supply Installation Instructions for more information.

1. Run a wire from the power supply to the leader cable connected to the first light bar in the run.
   NOTE: AC power connection must be contained in an acceptable enclosure .

2. Using twist-on wire connectors, connect the white/red stripe wire (+) from the light bar to the red wire (+) of the power supply. Connect the white wire (-) from the light bar to the black or blue wire (-) of the 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.

Retrofit Instructions

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 12.7mm (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 required number of LED modules required to illuminate the sign.
7. For UL retrofit sign conversions, the following 24VDC Class 2 Power Supplies must be used: GEPS24-25U-NA, GEPS24D-60U-GLX, GELP24-60U-GL, GEPS24D-80U, GEPS24-100U-GLX, GEPS24D-100U-NA, USVI-100024FE, USVI-100024FBA, GEPS24-100U-GLX2, GEPS24-100U-TT, GEPS24-200U-GLX2, GEPS24-300U-GLX2. 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 chosen.
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

All LEDs are OFF

| •    Check AC input connection and/or check 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 LEDs 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| •    Adjust LED layout to ensure uniformity of illumination on the face of the letter.

Maximum Remote Mounting Distance from Driver Output

Power Supply Wattage| 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| 66 ft./20.1 m| –| –| –
60W, 80W, 100W,

180W, 200W, 300W

| 5 ft./1.5 m| 8 ft./2.4 m| 14 ft./4.3 m| 22 ft./6.7 m

Parallel Wiring Option

Maximum Loading per 24 VDC Class 2 Power Supply

Power Supply

| GELW4871-1, GELW4865-1, GELW4850-1, GELW4841-1, GELW4832-1, GELW4850-1WH| ****

GELW1265-1

---|---|---
Rating (per Light Bar)| 24V, 696mA, 16.7W| 24V, 175mA, 4.2W
25W Power Supply

Load shall not exceed 1.04A

| 1 bars / 3 ft. 11-3/8 in. (1.20 m)| 5 bars / 5 ft. (1.53 m)
60W Power Supply

Load shall not exceed 2.5A

| 3 bars / 11.8438 ft. 10-1/8 in. (3.61 m)*| 13 bars / 13 ft. (3.96 m)
80W Power Supply**

Load shall not exceed 3.3A

| 4 bars / 15 ft. 9-1/2 in. (4.81 m)| 16 bars / 16 ft. (4.88 m)
100W Power Supply

Load shall not exceed 4.0A

| 5 bars / 19 ft. 9 in. (6.02 m)†| 20 bars / 20 ft. (6.10 m)††
200W Power Supply

Load shall not exceed 4.0A

per each (of 2) output channels

| 5 bars / 19 ft. 9 in. (6.02 m) per bank

10 bars / 39 ft. 6 in. (12.04 m) per PS

| 20 bars / 20 ft. (6.10 m) per bank

40 bars / 40 ft. (12.20 m) per PS

300W Power Supply

Load shall not exceed 4A

per each (of 3) output channels

| 5 bars / 19 ft. 9 in. (6.02 m) per bank

15 bars / 59 ft. 3 in. (18.06 m) per PS

| 20 bars / 20 ft. (6.10 m) per bank

60 bars / 60 ft. (18.30 m) per PS

Maximum Light Bars in Series connection (S)| 3 bars / 11 ft. 10-1/8 in. (3.61 m)| 11 bars / 11 ft. (3.35 m)

*GELP24-60U-GL minimum load = 2 bars / 7 ft. 10-3/4 in. (2.41 m) **GELP24-60U-GL minimum load = 5 bars / 5 ft. (1.52 m)
† Minimum load = 2 bars / 7 ft. 11 in. (2.41 m)
†† Minimum load = 8 bars / 8 ft. (3.05 m)

If you have any questions about these instructions or your specific application, please contact support at tetra.support@gecurrent.com. This product is intended solely for sign use only. Not intended for general lighting applications.
Conforms to the following standards : IP66. Acceptable for use in dry and damp locations.
The suitability of rain enclosure shall be determined if intended for wet location.

Electrical products must not be thrown out with domestic waste. They must be taken to a communal collecting point for environmentally friendly disposal in accordance with local regulations. Contact your local authorities or stockist for advice on recycling. The packaging material is recyclable. Dispose of the packaging in an environmentally friendly manner and make it available for the recyclable material collection service.

gecurrent.com/tetra
© 2022 Current Lighting Solutions, LLC. All rights reserved. Information and specifications are `subject to change without notice. All values are design or typical values when measured under laboratory conditions.

References

• Signage Lighting | Current - GLI Brands
• Homepage | Current - GLI Brands
• Signage Lighting | Current - GLI Brands
• LED Sign Lighting and Channel Letter Lighting | Current - GLI Brands

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