Installation Instructions: HYPERION R-Lite SYSTEM

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Eric McDaniel
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Installation Instructions: HYPERION R-Lite SYSTEM READ THIS MANUAL BEFORE PROCEEDING WITH THE INSTALLATION.

The 12-ft rule: keep the runs to 12-ft or under. Properly clean and prep the surface area that the strip will be applied to.

Using higher than 12AWG wire will result in increased voltage drop.

1 Installation Instructions: HYPERION R-Lite SYSTEM READ THIS MANUAL BEFORE PROCEEDING WITH THE INSTALLATION. FAILURE TO FOLLOW THE INSTALLATION INSTRUCTIONS WILL VOID YOUR WARRANTY! INSTALLATION TIPS Read this entire installation manual. The 12-ft rule: keep the runs to 12-ft or under. Properly clean and prep the surface area that the strip will be applied to. For Secondary Low Voltage Wiring use 10AWG or 12AWG Class 2 rated wire only. Using higher than 12AWG wire will result in increased voltage drop. Do not use wire nut connectors for connecting power connectors to secondary low voltage wiring. Use wire nuts to insulate only the ends of the low voltage wires. RETROFITTING OF UL LISTED SIGNS E / 7BA6 E Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 1 of 14

2 The main power to any existing system must be disconnected prior to the installation. The Accent system is intended to be used for new lighting systems or as a retrofit for existing neon, fluorescent or any combination thereof. When installing retrofit systems please refer to the existing products manufacturer for proper removal guidelines. All existing system components must be removed before installation of the Accent system. All removed material must be properly disposed of to meet your federal, state and local regulations. Install in accordance with the NEC and Local Electrical Codes. The Retrofit Kit System is to be installed in Listed Signs only. Hardware Screws IDC connectors Wire nuts Class 2 low voltage wire Tools Scissors Drill Screwdriver Pliers Optional Support Clamps Silicone For Retrofitting When installing retrofit systems please refer to the existing products manufacturer for proper removal guidelines. All existing system components must be removed before installation of the HYPERION R-Lite system. All removed material must be properly disposed of to meet your federal, state and local regulations. Note: After retrofitting is completed, all unused holes and openings must be sealed. Openings greater than 1/2 inch in diameter require a metal patch secured by screws and caulked with non-hardening caulk. Smaller openings can be sealed with non-hardening caulk. SURFACE PREPARATION Surface must be free of dust, dirt, grease, sharp objects, openings or corroded surfaces or other foreign material. Use non-oil based solvent (409, alcohol or heptane) to clean the surface. Area must be dry before application. HYPERION R-Lite strip bonds to all non-porous surfaces. Note: Application temperature range: 32 F to 100 F (0 C to 38 C). Note: If painting is necessary the paint must be dry before installation of strip. Note: Do not place the strip over sharp or non-flat objects or over patched holes. Note: It is recommended to test one or more letters before installation for acceptable color and illumination. REQUIRED FOR ALL FIELD RETROFITS To ensure adhesion of the HYPERION R-LITE strip to the back of the channel letter / cabinet place a plastic support clamp across the LED strip every 4 inches to mechanically secure the strip to the channel letter or cabinet. ( Att. 2) Note: Application temperature range: 32 F to 100 F (0 C to 38 C). Note: Do not place the strip over sharp or non-flat objects or over patched holes. Note: Do not drive the screw through the strip. Note: Do not put the clamp over any bends in the strip. ( Att. 2) Note: It is required that you utilize support clamps and/or a bead of silicone adhesive across the top of LED strip every 4 inches. (Continue to New Install) Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 2 of 14

New Install 1. Surface must be free of dust, dirt and grease. Use non-oil based solvent (409, alcohol) to clean the surface. Area must be dry before application.

Note: It is recommended to test one or more areas before installation for acceptable color and illumination. 2. Determine the linear footage required for each letter. Do not precut LED strips.

For white illumination, linear footage must be determined on a case to case basis to satisfy customer requirements. 3. Expose approximately 6 inches of the adhesive backing.

3 New Install 1. Surface must be free of dust, dirt and grease. Use non-oil based solvent (409, alcohol) to clean the surface. Area must be dry before application. The HYPERION R-Lite strip bonds to all non-porous surfaces. Note: Application temperature range: 32 F to 100 F (0 C to 38 C). Note: It is recommended to test one or more areas before installation for acceptable color and illumination. 2. Determine the linear footage required for each letter. Do not precut LED strips. Note: Always work from the R-Lite reel to avoid shortages and unnecessary use of jumpers. Note: In most cases, needed linear footage of HYPERION R-Lite strip is equal to neon. For white illumination, linear footage must be determined on a case to case basis to satisfy customer requirements. 3. Expose approximately 6 inches of the adhesive backing. Note: Do not touch adhesive tape with greasy or wet hands! 4. Adhere the HYPERION R-Lite strip inch by inch to the back surface of the channel letter. Note: Remember to place HYPERION R-Lite strip in the center of the channel letter. 5. To make a curve, bend the HYPERION R-Lite flexible conductor strip between the sockets pinching excess strip together between thumb and forefinger. After pinching adhere corner of the turn by firmly pushing down with your forefinger. Note: Do not put support clamps over any bends in the strip. 6. To trim HYPERION R-Lite strip to desired length, cut strip with scissors directly between sockets. Note: Do not make cuts near any socket. Do not use wire cutters or utility knives to trim the strip. Doing so may cause permanent damage to the strip Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 3 of 14

b) With thumb and forefinger at base of the connector and aligned parallel with the strip, place connector pins into socket and lightly push down on top of connector with forefinger until the

4 Installing Power Connector 1. a) Unplug the LED module from the socket. To remove the LED module, place thumb and forefinger on side edges of LED module and pull directly upwards until LED module is released from the socket. b) With thumb and forefinger at base of the connector and aligned parallel with the strip, place connector pins into socket and lightly push down on top of connector with forefinger until the connection is secure. c) Plug in previously unplugged LED module to the top of the power connector. Note: Do not tug on connector leads. d) Secure the connector with the connector holder and secure the connector cable with a 1/4 wire clamp. ( Att.1) 2. Drill a 1/4 (6.4 mm) hole into letter or raceway for connection wire access. Hole for connector wire should be off center and to the middle of the channel letter. Place protective rubber grommet on hole. Note: Do not drill through LED strip. Note for Halo-Lit applications: A UL-recognized clear acrylic or polycarbonate should be mounted on back of channel letter. Note: Maximum run length for each power connector is 12 linear feet. Installing Jumper Connector Some letters such as E, A or H require multiple strips of HYPERION R-Lite. In cases like this use single jumper connector to connect two separate runs as shown in picture below. Connect the jumper in the best possible area trying to avoid tight areas or severe bending or stretching of jumper. Please plan ahead when using multiple jumper connectors during installation. Note: Each jumper counts as 1-ft of LED strip and must be factored into the total footage of the power supply. 1. Attach one end of the jumper anywhere on the LED strip and secure with connector holder. 2. Attach the other end of the jumper to separate LED strip and secure with connector holder. Secure all wires with a 1/4 selfadhesive clamp. ( Att.1) Note: The joined LED runs MUST NOT exceed a combined total of 11 feet. Note: Only one jumper connector can be used per power connector. Using more than one jumper connector per power connector will result in voltage drop. Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 4 of 14

Group letters into equal load groups not to exceed the maximum load as listed in the Power Supply Loading Guidelines. ( Table 1) 2.

6 HRL-07-PFC-24 Power Supply Installation All secondary wiring must comply with Article 725 of the 2002 National Electrical Code (NEC). Class 3 or PLTC wire can be used as a substitution of Class 2 wire. Please refer to NEC Cable Substitution Hierarchy. 1. Group letters into equal load groups not to exceed the maximum load as listed in the Power Supply Loading Guidelines. ( Table 1) 2. Place the power unit in the middle of the selected load group as shown in the schematic drawing in attachment 3. Run a pair of Class 2 rated wires the length of the selected load group. ( Att.3) Note: Power supplies should be located within 25-ft of LED strip. Longer runs of 12AWG secondary wiring will decrease maximum allowable linear footage. Note: Using higher than 12AWG wire will result in increased voltage drop. Note: For wet locations, HRL-07-PFC-24 power unit must be installed in NEMA 3R enclosure or inside of the electric sign. Exit point of low voltage wiring must be secured against water entry into the box (rain tight bushing, cord grip etc.). Note: For dry or damp locations, HRL-07-PFC-24 power unit must be installed in NEMA 1 rated enclosure OR inside of all metallic enclosure, raceway OR a self-contained channel letter. 3. Connect power connector leads to Class 2 rated wires (parallel electrical connection) by using tap and run IDC connectors. Note: Do not use wire nuts for connecting power connectors to Class 2 rated wires! Note: Do not connect power supply outputs in series or parallel! 4. Use wire nuts to insulate ONLY the ENDS of the Class 2 wires. Secure Class 2 rated wires inside the raceway/wireway or on the wall with wire clamps. 5. Connect secondary/output wires from the HRL-07-PFC-24 power unit to Class 2 rated wires by using tap and run IDC connectors. ( Att.3) Important: Maximum load is 15 linear feet per power unit. 6. Secure power unit inside of electrical enclosure, channel letter or raceway. Note: Power unit should be secured at least 2 inches from the bottom of the raceway. Note: For wet locations, HRL-07-PFC-24 power unit must be installed in NEMA 3R enclosure or inside of the electric sign. Exit point of low voltage wiring must be secured against water entry into the box (rain tight bushing, cord grip etc.). Note: For dry or damp locations, HRL-07-PFC-24 power unit must be installed in NEMA 1 rated enclosure OR inside of all metallic enclosure, raceway OR as self-contained channel letter. Caution: Have a licensed electrician connect primary. Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 6 of 14

7 7. Connect the power unit to 120VAC junction box. Note: It is required to use UL rated metallic or nonmetallic conduit between the junction box and the power supply enclosure. Note: High voltage primary wiring, including wiring within 120VAC junction box, should comply with any applicable grounding and bonding requirements in Article 600 of the 2005 National Electrical Code (NEC). 8. Verify if disconnect switch is present. National Electrical Code (NEC) requires disconnect switch with all electrical signs. If disconnect switch is not present, it must be installed between main breaker and first power unit. Power Supplies will be used in listed signs only. Table 1: Power Supply Loading Guidelines HRL-07-PFC-24 Power Supply Outputs Output Voltage Minimum Linear Footage Maximum Linear Footage HRL-07-PFC VAC nom. No minimum 15 linear feet Attachment 3 Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 7 of 14

HRL-PSSQ-25 Power Supply Installation All secondary wiring must comply with Article 725 of the 2002 National Electrical Code (NEC). Class 3 or PLTC wire can be used as a substitution of Class 2 wire.

8 HRL-PSSQ-25 Power Supply Installation All secondary wiring must comply with Article 725 of the 2002 National Electrical Code (NEC). Class 3 or PLTC wire can be used as a substitution of Class 2 wire. Please refer to NEC Cable Substitution Hierarchy. 1. Group letters into equal load groups not to exceed the maximum load as listed in the Power Supply Loading Guidelines. ( Table 2) 2. Place the power unit in the middle of the selected load group as shown in the schematic drawing in attachment 3. Run a pair of Class 2 rated wires the length of the selected load group. ( Att.4) Note: Power supplies should be located within 25-ft of LED strip. Longer runs of 12AWG secondary wiring will decrease maximum allowable linear footage. Note: Using higher than 12AWG wire will result in increased voltage drop. Note: For wet locations, HRL-PSSQ-25 power unit must be installed in NEMA 3R enclosure or inside of the electric sign. Exit point of low voltage wiring must be secured against water entry into the box (rain tight bushing, cord grip etc.). 3. Connect power connector leads to Class 2 rated wires (parallel electrical connection) by using tap and run IDC connectors. Note: Do not use wire nuts for connecting power connectors to Class 2 rated wires! Note: Do not connect power supply outputs in series or parallel! 4. Use wire nuts to insulate ONLY the ENDS of the Class 2 wires. Secure Class 2 rated wires inside the raceway/wireway or on the wall with wire clamps. 5. Connect secondary/output wires from the HRL-PSSQ-25 power unit to Class 2 rated wires by using tap and run IDC connectors. ( Att.4) Important: Minimum load per power unit is 5 linear ft. maximum load 25 linear ft. 6. Secure power unit inside of electrical enclosure, channel letter or on the wall with three screws. Note: Power unit should be secured at least 2 inches from the bottom of the raceway / channel letter. Note: For wet locations, HRL-PSSQ-25 power unit must be installed in NEMA 3R enclosure or inside of the electric sign. Exit point of low voltage wiring must be secured against water entry into the box (rain tight bushing, cord grip etc.). Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 8 of 14

9 7. Connect the power unit to 120VAC junction box. Note: HRL-PSSQ-25 is equipped to accept 120VAC, 230VAC OR 240VAC. ( see Att.5 for wiring diagram) Caution: Have a licensed electrician connect primary. Proper connection is as follows: a) For 120VAC: Hot to Black & Yellow; Neutral/Common to Orange & White; DO NOT Connect BROWN and insulate end separately; Green: Ground b) For 230VAC: Hot to BROWN ; Neutral/Common to Orange; White & Yellow connected and insulate ends; DO NOT Connect BLACK and insulate end separately; Green: Ground c) For 240VAC: Hot to BLACK; Neutral/Common to Orange; White & Yellow connected and insulate ends; DO NOT Connect BROWN and insulate end separately; Green: Ground Note: HRL-PSSQ-25 power unit has a cutout for 1/2 conduit fitting. It is required to use UL rated metallic or nonmetallic conduit between the junction box and the power supply enclosure. Note: High voltage primary wiring, including wiring within 120VAC junction box, should comply with any applicable grounding and bonding requirements in Article 600 of the 2005 National Electrical Code (NEC) 8. Verify if disconnect switch is present. National Electrical Code (NEC) requires disconnect switch with all electrical signs. If disconnect switch is not present, it must be installed between main breaker and first power unit. Table 2: HRL-PSSQ-25 Power Supply Loading Guidelines Power Supply Outputs Output Voltage Minimum Linear Footage Maximum Linear Footage HRL-PSSQ VAC nom. 5 linear feet 25 linear feet Attachment 4 Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 9 of 14

HRL-PS96-70 Power Supply Installation All secondary wiring must comply with Article 725 of the 2002 National Electrical Code (NEC). Class 3 or PLTC wire can be used as a substitution of Class 2 wire.

11 HRL-PS96-70 Power Supply Installation All secondary wiring must comply with Article 725 of the 2002 National Electrical Code (NEC). Class 3 or PLTC wire can be used as a substitution of Class 2 wire. Please refer to NEC Cable Substitution Hierarchy. 1. Group letters into equal load groups not to exceed the maximum load as listed in the Power Supply Loading Guidelines. ( Table 3) 2. Place the power unit in the middle of the selected load group as shown in the schematic drawing in attachment 6. Run a pair of Class 2 rated wires the length of the selected load group. ( Att.6) Note: Power supplies should be located within 25-ft of LED strip. Longer runs of 12AWG secondary wiring will decrease maximum allowable linear footage. Note: Using higher than 12AWG wire will result in increased voltage drop. 3. Connect power connector leads to Class 2 rated wires (parallel electrical connection) by using tap and run IDC connectors. Note: Do not use wire nuts for connecting power connectors to Class 2 rated wires! Note: Do not connect power supply outputs in series or parallel! 4. Use wire nuts to insulate ONLY the ENDS of the Class 2 wires. Secure Class 2 rated wires inside the raceway/wireway or on the wall with wire clamps. 5. Connect secondary/output wires to power unit terminals 1 and 2. ( Att.6 ) Note: For better power distribution divide load between terminals 1 and 2. Important: Each terminal must be balanced within 10 linear feet of each other. Important: Minimum load per terminal is 10 linear ft., maximum load is 35 linear ft. 6. Secure power unit inside of the raceway or on the wall with four screws. Note: Power unit should be secured at least 2 inches from the bottom of the raceway. Note: For wet locations, HRL-PS96-70 power unit must be installed in NEMA 3R enclosure or inside of the electric sign. Exit point of low voltage wiring must be secured against water entry into the box (rain tight bushing, cord grip etc.). Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 11 of 14

12 7. Connect the power unit to 120VAC junction box. ( see Att.7 for wiring diagram) Caution: Have a licensed electrician connect primary. Note: HRL-PS96-70 is equipped to accept 120VAC OR 240VAC. Proper connection is as follows: a) For 120VAC: Hot to Black & Yellow; Neutral/Common to Orange & White; Green: Ground b) For 240VAC: Hot to Black: Neutral/Common to Orange; White & Yellow connected and insulate ends; Green: Ground Note: HRL-PS96-70 power unit has a cutout for 1/2 conduit fitting. It is required to use UL rated metallic or nonmetallic conduit between the junction box and the power supply enclosure. Note: High voltage primary wiring, including wiring within 120VAC junction box, should comply with any applicable grounding and bonding requirements in Article 600 of the 2005 National Electrical Code (NEC). 8. Verify if disconnect switch is present. National Electrical Code (NEC) requires disconnect switch with all electrical signs. If disconnect switch is not present, it must be installed between main breaker and first power unit. Power Supplies will be used in listed signs only. Table 3: HRL-PS96-70 Power Supply Loading Guidelines Power Supply Outputs Output Voltage Minimum Linear Footage Per Terminal Maximum Linear Footage Per Terminal Total Linear Footage HRL-PS VAC nom. 10 linear feet 35 linear feet 70 linear feet Attachment 6 Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 12 of 14

14 Troubleshooting Issue All letters are off Some letters are off Some LEDs appear dim or intermittent Shadows/uneven lighting Solution Check circuit breaker and AC input connection. Check power supply output connections and re-settable breakers (if applicable). Check IDC connectors to ensure they are fully connected. Check power lead wire connections on strip and verify connections are secure. (See Att. 1) Measure R-Lite strip length to ensure the maximum load length has not been exceeded. Be sure each jumper has been included in the overall footage for the power supply. Properly terminate the supply wire connection(s). Check IDC connectors to ensure they are fully connected. Check power supply output connections and re-settable breakers (if applicable). Check power lead wire connections on strip and verify connections are secure. (See Att. 1) Measure R-Lite strip length to ensure the maximum load length has not been exceeded. Be sure each jumper has been included in the overall footage for the power supply. Check IDC connectors to ensure they are fully connected. Check power supply output connections and re-settable breakers (if applicable). Measure R-Lite strip length to ensure the maximum load length has not been exceeded. Make sure the Class 2 wire has not exceeded the maximum length of 25-ft for remote mounting. Make sure Class 2 wire is not higher than 12AWG. Verify the max load length has not been exceeded and that wire connections and terminations are good. Re-route connecting wire and secure with wire clamps to ensure wire does not cover any of the LEDs. Copyright 2016 Revolution Lighting. All rights reserved. IN064_01_ Page 14 of 14

Installation Instructions: ACCENT SYSTEM

Installation Instructions: ACCENT SYSTEM READ THIS MANUAL BEFORE PROCEEDING WITH THE INSTALLATION. FAILURE TO FOLLOW THE INSTALLATION INSTRUCTIONS WILL VOID YOUR WARRANTY! INSTALLATION TIPS Read this entire