Sylvania BACKlight 2nd Generation BL02 User manual

BACKlight 2nd Generation modules from OSRAM
SYLVANIA are durable, energy-efficient, and long-life
LED light source alternatives to neon. Their flexible,
chain configuration make them ideally suited to fit
contours and curves typical to channel letter signs.
The BL02 and BL04 LED modules are optimally oper-
ated with OPTOTRONIC®10.5Vdc power supplies.
This installation guide outlines step by step instruc-
tions to properly install both BACKlight BL02 and
BL04 modules for backlighting channel letters and
other signage applications.
WARNING: ONLY QUALIFIED PERSONNEL SHOULD PERFORM INSTALLATION.
TO AVOID ELECTRICAL SHOCK OR COMPONENT DAMAGE, DISCONNECT POWER BEFORE ATTEMPTING
INSTALLATION OF THE POWER SUPPLIES AND/OR MODULES.
Failure to install the power supplies and/or LED modules in accordance with the National Electric Code (NEC), all applicable
Federal, State and local electric codes as well as the specific Underwriter’s Laboratories (UL) safety standards for the
installation, location and application may cause serious personal injury, death, property damage and/or product malfunction.
These instructions are guidelines for installation of OSRAM LED modules and power supplies. Installation requirements may
vary depending on the application. Licensed electricians should provide all installation services for connection of both primary
and secondary (input/output) of the power supplies.
BACKlight 2nd Generation
Installation Guide
(BL02 and BL04 Modules)
www.sylvania.com

The BL02 module is 15.75' long and
consists of 60 circuit boards (each
with two LEDs) separated by 3" wire
interconnects. A complete reel (31.5')
consists of two such modules. Available
colors include super red, amber red,
yellow, orange, green, blue and 5400K
and 6500K white. The BL02 LED mod-
ule is listed in the UL Sign Components
Manual (SAM). For more product de-
tails, please refer to Product Information
Bulletin # LED033.
The BL04 module is 8.0' long and
consists of 30 circuit boards (each with
4 LEDs) separated by 3" wire intercon-
nects. A complete reel (16.0') consists
of two such modules. Available colors
include green, blue, 5400K and 6500K
white. The BL04 module is listed in the
UL Sign Components Manual (SAM).
For more product details, please refer to
Product Information Bulletin # LED046.
OSRAM OPTOTRONIC 10.5Vdc
power supplies are compact and
electronically stabilized. They are
protected against open circuit, short
circuit, overload, and overheating
conditions. The power supplies are
UL recognized and FCC compliant.
For more product details, please
refer to Product Information Bulletin
# ECS049.
Recommended Information
Bill of Materials (BOM), LED layouts,
or specific instructions from sign
manufacturer/owner if available
OSRAM SYLVANIA LED Specification
Guide (LED028) or Product Inform-
ation Bulletins
Regulatory Literature (electrical
codes, etc.)
For retrofit applications, please refer
to the application note “Estimating
Quantity of OSRAM BACKlight LED
Modules Needed to Replace Neon
in Channel Letter Sign” (LED024)
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Materials and Accessories (supplied
by manufacturer as listed, otherwise
supplied by contractor)
All power leads should have a
minimum rating of 18 AWG
Cable ties
Wire nuts
Strain reliefs
Connectors (Item Number 70126 or
other types) approved for outdoor
or damp location installation
Mounting tape (Item Number 70125
or other types) approved for outdoor
or damp location or BL-T Installation
Aid (Item Number 70296)
Mounting screws #4 x3/8 or
#6 x3/8 sheet metal screws
(plastic washer with outside
diameter no bigger than ¼")
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Tools:
Wire stripper/cutter
Screwdriver
Tape measure
Drill and drill bits (3/32 drill bit
is recommended for #4 3/8
metal screw)
Rivet tool and rivets (#8)
Multi-meter, power meter
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Products Covered
BACKLIGHT 2ND GENERATION INSTALLATION GUIDE

Installation Steps:
Step
1
Step
2
Step
3
Step
4
Material Check
Verify that you have sufficient power
supplies and LED modules on hand
to complete the project. DO NOT
proceed with the installation if there
are missing or damaged materials.
WARNING:
DISCONNECT ALL EXISTING
ELECTRICAL CONNECTIONS
TO THE POWER LINES and
secure the input power cables
for safety.
Prepare the
Channel for
Product Installation
For retrofits, remove the old materials
Mark the installation hole locations of
LED boards and power supplies onto
the mounting plane of the letter channel
Drill the installation holes for installing
products or mounting accessories
Remove any metallic debris, degrease
and clean the surface
Mount any accessories for installing
the LED boards
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Power Supply
Installation
Use 2 screws per power supply to
firmly secure the product in place.
Power supplies should be installed
in compliance with all applicable
electrical code requirements.
CAUTION: Do not connect the input
power cables to the power supply at this
step until the LED board installation is
complete. Start the cable connection
from the LED boards and work all the
way back to the power supplies, then
to the electrical power box.
LED Module
Installation
Place the LED module in position
and make any necessary adjustments
Cut the module at the length or
number of boards as required
Cutting instruction:
For White, Blue and Green,
cut conductors between coupons
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For Super Red, Amber Red, Orange, and Yellow
Cut ONLY at 2-conductor locations
Secure the boards using mounting tape,
BL-T mounting accessory, screw or rivets
NOTE: The brightness and uniformity
of the face of the sign can be controlled
and tuned by adjusting the spacing
between LED boards and the number
of boards per unit area.

LED Wiring and
Connection to the
Power Supply
Check polarity. For all B2G models,
the wire color code for polarity is:
White = +10 Vdc
White/Blk = GND
Connect all LED sections to make a
continuous LED strip using appropriate
wire connectors
Connect the LED strips to the power
supplies using appropriate electrical
wires and connectors
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Connect Low Voltage
Power Feed Wires to
the Power Supply Leads
Use appropriate wire nuts or other
wire connectors
Connect the Power
Supply Leads to the
Power Line Leads
If necessary, connect jumpers with suf-
ficient length to the power supply input
leads in order to reach the power lines
For remote installations of power sup-
plies, DO NOT connect to the power
lines before installation is complete
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Complete Power
Line Connection
Connect the input power cable to the
power line and verify proper operation.
If installation does not work, discon-
nect the main power, refer to Table 3
“Troubleshooting” in Appendix or
consult with a qualified electrical
engineer and make corrections
required.
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Step
5
Step
6
Step
7
Step
8

No. Symptom Possible Cause Corrective Action
1. No Light No input Voltage/ Power Check the Power switch; it should be ON.
Make sure the power switch or circuit breaker is working properly.
Output Voltage of the power supply is 0 Check if the input wires are energized.
Make sure the power line wire connections are done properly.
Check the input voltage; it should be 120Vac or the value of the power line.
Connect properly to the power line.
Disconnect the LED strips from one wire of the power supply.
If the output voltage is 0, replace the power supply.
If the output voltage is alright, check the polarity or look for wire shorted.
2. Sections of the Faulty wire connection Wiring issue: • check polarity • check the continuity • check the wire connections
installation are not lit Make the corrections to the wiring.
Defective LED strip Power up that section from a new power connection.
If all above are done properly and it is still not working, replace that LED module section.
3. LEDs are blinking Under load Check the under load limitation for the power supply used. Select the proper power supply.
Overload Check the power required by the LED strips installed. Select the proper power supply or use
additional power supplies to eliminate the overload condition.
4. Overheat or smell Wrong input voltage for power supply Check if the voltage of the power line is the one required by the power supply used.
of burnt materials Use the power supply with the proper voltage for the power line voltage.
Wrong input voltage from power supply Check if the output low voltage is 10.5 +/- 0.5 Vdc. Replace the power supply
with the proper model for the LED module used.
5. Shadows on the face Layout issue Check the uniformity of the LED sections layout. Correct the layout.
Section NOT working properly Check if all LED sections are working properly. Correct/eliminate the cause.
6. Hot spots on the face Layout issue Check the uniformity of the LED sections layout. Correct the layout.
Section NOT working properly Check if all LED sections are working properly. Correct/eliminate the cause.
APPENDIX:
1. Recommended Maximum OPTOTRONIC 10.5Vdc Power Supplies Remote Mounting Distance
3. Troubleshooting Table
2. Power Supply Requirements
LED LOAD
WATTAGE 14 AWG 16 AWG 18 AWG 20 AWG 22 AWG
20 52 33 21 13 8
25 42 26 17 11 7
30 35 22 14 9 6
35 30 19 12 8 5
40 26 16 10 7 4
45 23 15 9 6 4
50 21 13 8 5 3
OPTOTRONIC 25W (51505, 51506) OPTOTRONIC 50W (51508, 51509)
Max. Length
Item Ordering Maximum LED Load No. of Maximum LED Load No. of per power feed
Number Description Color Length (ft) Watts Modules Length (ft) Watts Modules connection (ft)
70271 B2G/BL02S/W3-854 31.5 White 17.8 24.9 1.1 35.5 49.7 2.2 15.8
70272 B2G/BL02S/W3-865 31.5 White 17.8 24.9 1.1 35.5 49.7 2.2 15.8
70144 B2G/BL02S/W2-865 31.5 White 20 24 1.3 41 50 2.6 15.8
70239 B2G/470/BL02/B1 31.5 Blue 24 24 1.5 49 50 3.1 15.8
70238 B2G/525/BL02/T2 31.5 Green 24 24 1.5 49 50 3.1 15.8
70237 B2G/587/BL02/Y2 31.5 Yellow 20 24 1.3 41 50 2.6 15.8
70236 B2G/606/BL02/O1 31.5 Orange 20 24 1.3 41 50 2.6 15.8
70175 B2G/617/BL02/A2 31.5 Amber Red 20 24 1.3 41 50 2.6 15.8
70235 B2G/633/BL02/S1 31.5 Super Red 20 24 1.3 41 50 2.6 15.8
70274 BACKlight2G/BL04S/W3-865 White 8.75 24.5 0.6 17.8 49.7 1.1 8
70273 BACKlight2G/BL04ST/W2-865 White 10 24.1 0.6 20 48.2 1.3 8
70171 BACKlight2G/470/BL04ST/B1 Blue 12 24 0.8 25 50 1.6 8
70172 BACKlight2G/525/BL04ST/T2 Green 12 24 0.8 25 50 1.6 8
NOTE: The maxium remote mounting distance for OPTOTRONIC
power supplies is specified in the power supply data sheets.
Although it is possible to exceed these distances, the installer
and/or end user must take precautions to prevent and/or test
the effects of EMI (electromagnetic interference).
Distance (ft)

LED032R1 4/08
OPTOTRONIC and OSRAM are registered trademarks of OSRAM GmbH.
SYLVANIA is a registered trademark of OSRAM SYLVANIA Inc.
OSRAM SYLVANIA
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Service and Sales Center
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Westfield, IN 46074 USA
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Phone: [phone]
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Headquarters
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Mississauga, ON L5S 1S4
Industrial Commercial
Phone: [phone]
Fax: [phone]
Special Markets
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Visit our website: www.sylvania.com
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