AGM D-Lux LED Retrofit Installation instructions

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
D-Lux LED Retrofit
Installation and Owner’s Manual
D-Lux LED Retrofit Installation – March 2014 Page | 1

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
D-Lux Retrofit Kit Catalog Numbers
D7-XXX0RTR
Catalog Code
Sign Size Modules
1= Size 1 1.0 to 4.0 in length (whole mods only)
2= Size 2
3= Size 3 Sign Style
2= Style 2 (3 step 4.8A – 6.6A)
3= Style 3 (5 step 2.8A – 6.6A)
5= Style 5 (1 step 5.5A)
L830 Requirements, VA Loads, Power Factors1for LED Board Light Source
Size
Style
Modules
L830
Transformer
VA*
Power
Factor*
# of Lamps
1
2 & 5
1.0
65W
39
0.93
2
1
2 & 5
2.0
65W
44
0.93
4
1
2 & 5
3.0
65W
49
0.94
6
1
2 & 5
4.0
65W
54
0.94
8
2
2 & 5
1.0
65W
41
0.93
3
2
2 & 5
2.0
65W
49
0.94
6
2
2 & 5
3.0
65W
56
0.94
9
2
2 & 5
4.0
65W
65
0.94
12
3
2 & 5
1.0
65W
44
0.93
4
3
2 & 5
2.0
65W
54
0.94
8
3
2 & 5
3.0
65W
65
0.94
12
3
2 & 5
4.0
100W
77
0.93
16
1
3
1.0
65W
39
0.93
2
1
3
2.0
65W
44
0.93
4
1
3
3.0
65W
49
0.94
6
1
3
4.0
65W
54
0.94
8
2
3
1.0
65W
41
0.93
3
2
3
2.0
65W
49
0.94
6
2
3
3.0
100W
57
0.94
9
2
3
4.0
100W
69
0.94
12
3
3
1.0
65W
44
0.93
4
3
3
2.0
65W
54
0.94
8
3
3
3.0
100W
69
0.94
12
3
3
4.0
200W
77
0.93
16
* These ratings are subject to change without notice.
1Power factors are measured on the primary of the corresponding L830 transformer, per FAA Circular 150/5345-44J. This
takes into account the inherent deficiencies of the isolation transformer in the values.
D-Lux LED Retrofit Installation – March 2014 Page | 2

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
Inspection and unpacking
When unpacking each kit, check that the LED mounting brackets are not bent or damaged from
shipping. Make sure to note any damage that occurred during shipping when receiving the retrofit
kit and be sure to document it with the carrier. When installing the retrofit kit, make sure that the
correct L830 isolation transformer is connected.
Identify the components with different type and length wire harnesses. An inventory of each kit
can be found on pages 14 to 16. Power to driver wire harnesses have 4wires and a ferrite coil at
one end, as shown on pages 5 to 8. They are already plugged into the driver modules and ready
to be routed back to the power supply output. LED to LED wire harnesses have 5wires and are
plugged into the bottom of the driver modules, ready to be routed to the IN connection of an LED
board on a mounting bracket. Additional LED to LED wire harnesses may be plugged into the
OUT connection of a LED board on one mounting bracket to connect to an IN connection of an
LED board on an adjoining bracket. Mounting brackets are numbered from 1 to 4; number 1 is
closest to the power cord.
Useful tools to complete the retrofit are:
•Wire cutters & strippers;
•Drill with 9/64” bit and 5/16” bit;
•Countersink bit;
•#2 Phillips screwdriver and a deep 3/8” socket; and
•5/16” nut driver.
D-Lux Retrofit Installation
1. Make sure the circuit is turned off and locked out.
2. Remove the top of sign on the module where the power cord enters. Remove the panel on the
side that is easiest to work on (downwind). Replace the top after removing the panel (this will
maintain the width of the module while the light bar assembly is replaced).
3. Cut or disconnect the power cord as close to the existing power control module (PCM) as
possible. Leave enough slack to strip the ends and crimp on 1/4” female spade connectors.
4. Remove the existing light bar assembly from the first module where the power enters, and
install the replacement light bar assembly shipped with the retrofit kit. Cut off any old wiring
that extends into connecting modules. The replacement light bar assembly should be oriented
with the rectifying bridge closest to the power end of the sign. Mounted on the underside of the
replacement light bar assembly, the rectifying bridge is a black 1” square, 1/4” thick with 4,
1/4” spade terminals, two of which have a black and a red wire connected to the LVCV2 PCM.
If the holes on the end of the light bar do not line up directly with the holes on the castings, use
a 5/16” drill bitto run through the casting tabs to widen and align the holes. Insert the bolts and
washers, and attach the K-Lock nuts to secure the light bar assembly to the sign module.
Once secure, the top of the sign can be removed and set aside.
5. The GDT surge protector is connected to the rectifying bridge and will have two insulated 1/4”
male spade terminals open where the power cord is [to be] connected. Crimp the 1/4” female
spade connector terminals contained in the hardware kit on the ends of the power cord that
have been stripped back 1/4” from where they were cut. Connect the male terminals of the
GDT to the female terminals of the power cord.
D-Lux LED Retrofit Installation – March 2014 Page | 3

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
(a)
(b)
(c)
Speed nut clip LED mounting bracket
6. The LED brackets are attached across the top of the sign module. Begin
by drilling out the existing rivets and speed nut screw clips on the top of the
module castings. After the rivets and the speed nut screw clips are removed,
countersink the hole to accommodate the new screw head. Holes may
already be countersunk (a). Just make sure the tops of the 6 x 32 flat head
screws lie at or below the casting surface before continuing.
7. Insert the 6 x 32 flathead screws from the hardware kit into the holes.
8. Bring the LED mounting bracket into the module (note which direction to
insert it based on the wiring diagrams on the next page), and raise it up to the
top of the module (b) so the screws are extending through the recesses on
either side of both ends. This is best accomplished with an assistant to hold
the LED mounting bracket in place while the next steps are completed.
9. With the LED mounting bracket held in place, insert the replacement speed nut screw clips on
the protruding screw ends, and secure them in place using the nylon lock nuts from the
hardware kit.
10. Using a 5/16” nut driver (or wrench), tighten the screw so the tip of it just passes through the
nylon retainer of the nut. It is important not to tighten the speed nuts too much in order for the
speed nut clip to find the speed screw easily. The whole assembly will be secure when the
thumb screws that hold the tops on are tightened (c).
11. Connect the 5 wire LED to LED harnesses from the driver module, up the tree castings and
into the IN connection of the first LED mounted on the LED light bracket, per the wiring
diagrams on pages _ to _. Note any configuration where one LED light bracket connects to the
next between modules using the 12” five wire harnesses.
12. If more than one driver is required for the retrofit, note in which module it is located as
described on the wiring diagram, and follow the same procedure from step 4 to install it. Note
on the wiring diagram, upon which end the driver is located. Connect the additional driver to
the LVCV2 power supply using the 4 wire power to driver wire harnesses, making sure to plug
the 1/2” ferrite end of the wire harness into the LVCV2 and the other end into the single plug
location on the driver.
13. Plug the additional LED light brackets into the extra drivers on all the connections per the
drawing.
D-Lux LED Retrofit Installation – March 2014 Page | 4

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
14. Restore power to the sign, and verify operation.
15. When operation is confirmed, use the u-clips included in the hardware kit to secure any slack
wire to the light bar assemblies.
16. Replace panels and secure the tops of the sign.
D-Lux LED Maintenance
AGM signs are designed to provide years of trouble-free service. Prior to the performance of any
work on the signs, power must be disconnected and locked out at the vault. We recommend an
annual inspection & wiping down of the sign interior to maintain bright and even light output.
Inspection of the signs should also include removal of any excess dirt, snow, and avian excrement
to maintain proper visibility of the sign legend.
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D-Lux LED Retrofit Installation – March 2014 Page | 5

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
D-Lux LED Wiring Diagram
D-Lux LED Retrofit Installation – March 2014 Page | 6

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
AGM D-Lux LED Size 1 Wiring Schematic
D-Lux LED Retrofit Installation – March 2014 Page | 7

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
AGM D-Lux LED Size 2 Wiring Schematic
D-Lux LED Retrofit Installation – March 2014 Page | 8

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
AGM D-Lux LED Size 3 Wiring Schematic
D-Lux LED Retrofit Installation – March 2014 Page | 9

108 Fairgrounds Drive Suite 8
Manlius, NY 13104
Phone: [phone]
Fax: [phone]
www.agmsigns.com
D-Lux Sign Dimensions
A
B
C
D
X
Y
Z
H
Size 1
30.0
59.0
88.0
117.0
7.75
14.63
13.0
26.5
Size 2
37.5
73.75
110.0
146.3
9.125
18.5
14.63
32.75
Size 3
41.88
83.75
125.6
164.5
10.5
21.0
15.88
38.5
Size 5
41.88
na
na
na
10.5
21.0
15.88
38.5
A = length of one module
B = length of two modules
C = length of three modules
D = length of four modules
X = length from end of sign to first frangible leg
Y = length between frangible legs
Z = maximum sign width
H = maximum sign height
Floor Flange
Dimensions
D-Lux LED Retrofit Installation – March 2014 Page | 10