Flush Mount Channel Letter Installation Instructions - Neon Illumination


NEON Channel Letter Installation Instructions - Flush Mount

This sign is intended to be installed in accordance with the requirements of Article 600 of the National Electrical Code and/or other applicable local codes. This includes proper grounding and bonding of the sign.

1. Refer to the drawing included with the letter set that depicts the arrangement of the subassemblies.

2. Unroll paper pattern, and tape to substrate. Level and center pattern on wall. Drill holes for secondary high voltage whips and mounting holes, and then remove pattern. Mount letters on the wall using the drawing as a guide. If letter set does not have rivet nuts, remove faces push secondary high voltage whips (run in metal conduit) through substrate, mount letters onto substrate, and then replace faces. If the letterset does have rivet nuts, install threaded rod into rivet nuts then push secondary high voltage whips (run in metal conduit) through substrate and secure with hardware from the back side of substrate.

3. Refer to wiring diagram below (figure 1) and the transformer breakdown diagram (provided with letter set) to splice the secondary conductors (GTO). Each secondary circuit has a dedicated transformer and is color coded on the transformer breakdown sheet. Connect one GTO wire from the outside two letters (sections) of each secondary circuit to the transformer as specified per the manufacturer’s instructions included. Complete the secondary circuit by splicing the remaining GTO wires in series, as follows: Splice the second GTO lead from one outside letter to one of the GTO wires from the adjacent letter. Then splice the second wire from this letter to one GTO wire from the letter adjacent to it. Continue this process until the second lead from the second outside letter is spliced. Connect all GTO wire splices as specified per the splice box manufacturer’s instructions included. Repeat this process for each secondary circuit.

4. All OUTDOOR secondary wiring must be run in bonded ½" Sealtite, or ½" EMT with appropriate connections.

5. Mount the transformer boxes; OPEN SIDE UP, as close as possible to the center of the two GTO whips (1/2" flexible conduit) that will be connected to it. It should be mounted at the same height as the letter set to minimize GTO whip lengths.

6. GTO whips (1/2" flexible conduit) from letter to letter or letter to transformer box can be no longer than 6’. MAKE EVERY ATTEMPT TO KEEP THE GTO WHIPS AS SHORT AS POSSIBLE.

7. Install the transformer in the box as specified per the transformer box manufacturer’s instructions included.

8. Fasten the whips (flexible conduit) to the end of the transformer box closest to the high voltage terminal that the GTO will be connected to. Ensure that a proper bond is made between the conduit and the transformer box.

9. Route the GTO inside the transformer box from the conduit to the high voltage terminal on the transformer in such a manner that the primary electrical wires can enter the transformer box and stay AT LEAST 2" AWAY, from the GTO at all times.

10. Securely fasten the GTO to the transformer as specified per the transformer box manufacturer’s instructions included.

11. Connect the primary electrical supply to the transformer per the transformer manufacturer’s instructions included.

12. Repeat the steps above for each transformer circuit.

13. At least one On/off switch, rated for the application, must be installed on the primary "hot" lead within the line of sight of the transformers.

14. Signs cannot be connected to a branch circuit exceeding 30 amperes.