Download 3635-1000 Light Mat Series

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Installation Bulletin 3635-1000
3
Release D, Effective July 2010 (Replaces C, Apr 2010)
See Bulletin Change Summary at end of Bulletin
Installation Instructions
3M™ Light Mat Series 3635-1000
Product Description
This is a highly-reflective adhesive-backed film embedded with warranted, energy-efficient
LED lights. Brightness is customer-configured by LED placement for excellent color balance
and uniform illumination in enclosed sign boxes. Flexible and conformable to almost any size,
unique shape or curve, it installs easily in existing sign boxes or slim-profile sign boxes.
Product Numbers
3M™ Light Mat Series 3635-1000. Refers to any configurations of light mat
3M™ Light Mat 3635-1030. Refers to a parallel circuit light mat with 0.030 amp LEDS
3M™ Light Mat 3635-1 X A A. Refers to a custom light mat:
1X = type of circuit
AA = current rating of LEDs
If X = 0, then parallel circuit
If X = 1, then series circuit
Product Specifications and
Warranty Information
Please see Product Bulletin 3635-1000 for product details and completed warranty
information. It is available at www.3mgraphics.com/lighting.
Health and Safety
!
WARNING
Risk of Electric Shock or Fire
To reduce the risk of exposure to hazardous voltages, which could result in death, serious
injury, or property damage
• Be sure your power supply is certified as Class 2 and/or LPS (Limited Power Supply).
• Class 2 and/or LPS, less than 100 Watts, constant current.
!
WARNING
Risk of Exposure to Hazardous Voltages
To reduce the risk of exposure to hazardous voltages, which could result in death, serious
injury, or property damage:
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Be sure your power supply is certified as Class 2 and/or LPS.
Class 2 and/or LPS, less than 100 Watts, constant current.
Disconnect line power to power supply before attempting installation.
Use care in working around the high voltage input to power supply.
Never install with low voltage wiring coming into close proximity with high voltage input
lines.
• Always install according to all local, state and national codes.
Installation Bulletin 3635-1000 - 1
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WARNING
Use a Licensed, Qualified Electrician or Sign Installer
Installation should be performed by a licensed, qualified electrician or sign installer who is
familiar with electrical sign installations. Installation should comply with the National Electrical
Code (NEC) and all state and local codes
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CAUTION
Avoid Damaging Light Mat with Electrostatic Discharge
The 3M Flexible Light Mat contains parts and assemblies susceptible to damage by
electrostatic discharge (ESD). To ensure that the 3M Flexible Light Mat is not damaged by
ESD, ensure there is a proper earth ground for each sign box or section containing Light Mat.
!
WARNING
Risk of Fire
To reduce the risk of fire, do not connect outputs of Class 2 or LPS power supplies together.
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CAUTION
When handling any chemical products, read the manufacturers' container labels and the
Material Safety Data Sheets (MSDS) for important health, safety and environmental inform­
ation. To obtain MSDS sheets for 3M products go to 3M.com/MSDS, or by mail or in case of
an emergency, call 1-800-364-3577 or 1-651-737-6501.
When using any equipment, always follow the manufacturers' instructions for safe operation.
Electrical Rating
for Light Mat
Nominal Voltage
1.8 - 20V
1.8 - 24V
1.8 - 42V
Light Mat Installation Kit
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Light Mat assemblies with leads attached
Wire connector(s)
Assembly diagram
Wiring diagram
Low voltage Class 2 power supply with manufacturers installation instructions.
Power Supply Ferrite; only if supplied with Advance Power Supply LEDINTA 0024V41FO
Light Mat Installation Instructions
Tools and Supplies
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Non-conductive caulk for void and/or perimeter areas, such as DOW Corning 748 RTV
Diagonal wire cutter
Utility knife
Wire stripper
Digital multimeter
3M™ Foam Applicator TSA-1
Isopropyl alcohol (IPA)
Helpful but not required or supplied
Max Amperage
5A
4.16A
2.0A
Max Watts per Channel
100W
100W
100W
Installation Bulletin 3635-1000 - 2
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Remove Existing Electrical
Components
• For retrofit applications the light mat and power supply are
each marked with the UL Classification Mark.
For retrofit kits only
• The retrofit kit is intended to be used with UL Listed neon
or fluorescent channel letter or box signs of the neon or
fluorescent type.
• Do not remove or paint over the original UL Listing Mark
on the sign.
• Leave one copy of these installation instructions and the
power supply installation instructions with the building
owner or tenant for use by the local authority having juris­
diction or electrical inspector who will need them in order
to approve the installation.
Removal Procedure
1. Disconnect the main power to the sign by turning off the disconnect switch and the main
circuit breaker.
2. Verify that the main power is off and any exposed electrical conductors are de-energized.
3. Disconnect the wires connecting the existing power transformer or ballast from the line
supply side.
! WARNING
Avoid Interference with New Components
All existing electrical components within a sign must be removed to avoid interference with
new components. For neon signs these components may include some or all of the following:
neon tubes, tube supports, neon power supplies and all secondary wiring. For fluorescent
signs these components may include some or all of the following: fluorescent tubes, lamp
sockets, ballast, and ballast secondary wiring.
4. Remove all existing transformers or ballasts.
5. Remove and replace any electrical enclosures that are corroded or damaged. If the
existing enclosure is removed, replace with a properly sized enclosure as specified by the
power supply manufacturer. Verify any self-contained power supplies not requiring an
enclosure, installed outdoors, not under a roof or canopy are classified as "Wet" rated.
6. Carefully remove all glass tubes, tube supports, sockets and secondary wiring. Ensure
that all removed material is disposed of properly according to your local regulations.
7. Except for those holes intended for ventilation and Class 2 power feed, all unused holes
and openings must be sealed.
8. If an additional secondary wire is required, UL Listed PLTC Cable marked "Sunlight
resistant (if exposed to weather) is recommended for connection of the light mat to the
power supply.
9. Reconnection of line voltage must be in compliance with all Federal, State and Local
electrical codes.
Installation Bulletin 3635-1000 - 3
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Cutting the Light Mat
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CAUTION
Avoid Damage to Copper Circuits when Cutting, Which May Result in Electrical Shorts
The Light Mat contains two copper circuits separated by non-conductive film. A cut through
the copper circuitry must not create burrs or edge artifacts that allow circuits to contact each
other. Contact between the circuits will short out the Light Mat and cause it to fail.
The following cautions must be observed when cutting the Light Mat:
• NEVER cut through the copper embedded in the Light Mat while Light Mat is powered,
illuminated or energized.
• Any cut to the Light Mat must be at least 1/4 inch (63 mm) away from any LED on the
Light Mat. This includes trimming as well as holes cut to feed through wires and attach
mechanical fasteners.
• There must be a margin of at least 1/4 inch (63 mm) from the edge of the Light Mat to
any sidewall of the light box.
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Circles represent areas through
which you can cut. Notice the
dashed lines showing potential
cutting paths.
DO NOT CUT through the
rectangular areas, which represent
double layer copper.
If Cutting Is Needed
3M Light Mats are engineered to your specifications and should not need to be modified.
However, if you need to trim or cut the light mat, to maintain the integrity and life of the light
mat, you must use perimeter caulk for any cut or damaged areas.
Perimeter Caulking
If the copper circuitry in the Light Mat is exposed due to cutting or damage, the exposed cir­
cuitry must be sealed or protected from contact with metal surfaces or objects. To protect it,
seal the exposed circuitry with a non-conductive caulk such as DOW Corning 748 RTV.
Power Supplies
All Light Mat kits used for the creation of new or retrofit
applications will be provided with a UL Recognized Sign
accessory Class 2 power supply.
For Retrofit applications the power supply will also be marked
with the UL Classification Mark
• Power Supply-R/C (UYMR2), a component sign accessory, LED power supply, is provided
with a retrofit kit meeting the following specifications:
- Marked “Class 2” with an output rating suitable for the intended load and not ex­
ceeding 42.2 VDC maximum.
- Power supply may have single or multiple Class 2 outputs.
- Marked for “damp location”.
- Only LED power supplies with integral input lead wires may be specified.
- Supplies are identified for use in a minimum recommended ambient temperature of
40 C. (marking on power supply)
Power Supplies continued on the next page.
Installation Bulletin 3635-1000 - 4
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• All installations must comply with UL conditions of use as noted in the power supply man­
ufacturers installation instructions and in the UL Sign Components Manual (SAM)
(http://www.ul.com/global/eng/pages/offerings/industries/lighting/signs/manual/).
• No more than four LED drivers may be installed on a branch circuit.
• The power supply including input wiring shall be mounted inside a UL Listed sign raceway
or electrical enclosure, or inside a remote mounted electrical enclosure having a UL Sec­
tion of Sign UL Listing Mark. The source ground and power supply case should be elec­
trically tied to the electrical enclosure.
- If minimum size enclosure is specified by the power supply manufacturer It is recom­
mended to use the smallest size enclosure recommended by the manufacturer.
- If multiple LED power supplies are installed they must not be mounted closer than
1 inch end to end and 4 inch side to side and there shall be no interconnection
between separate Class 2 output circuits or wiring.
- Power supplies have ferrites attached for FCC Class A compliance. To be effective
the ferrites must remain in place. DO NOT remove the ferrites.
- For Light Mat kits supplied with Advance Power Supply LEDINTA0024V41FO, a sep­
arate ferrite is supplied which is to be installed on the AC input side of the power
supply. One pass through the center of the ferrite of the Line, Neutral and ground
wires is required for installation.
• Individual installation environments will vary. Be sure power supply installation complies
with environmental conditions of use (wet or dry and proper spacing of power supplies
within the enclosure) before completing installation.
• Power supply installation instructions are included in all retrofit kits. Read all installation
instructions before attempting to install the Light Mat. Installation of Light Mat kits should
be performed by a qualified electrician or sign installer.
Surface Preparation
1. Make sure the surfaces and areas where the Light Mat will be applied are clean and free
of dirt, grease, oil and debris.
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Remove all metal cuttings and burrs from application surfaces.
Wipe all application surfaces with Isopropyl Alcohol (IPA) and dry with a lint-free cloth.
2. Be sure the application surface is at least 40_F (4.5_C) and that it is clean and dry.
Installation
Install the Light Mat
1. Locate the Light Mat component in the sign
box according to the sign box assembly
instructions and temporarily secure.
2. Position the mat, using strips of Scotcht
Masking Tape to hold the mat to the
substrate. Then, apply a strip of masking
tape 2 to 3 inch (5.1 to 7.5 cm) wide,
horizontally across the top of the mat. See
FIGURE 1.
FIGURE 1
Make a Top Hinge
Installation Bulletin 3635-1000 - 5
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3. Raise the mat up over the top of the hinge
and peel the liner back a few inches. See
FIGURE 2.
Note:
The entire liner may be removed at this
time, if desired. However, for very large
mats, leaving the liner in place just
prior to rolling to adhere it makes the
mat more controllable, keeps the
adhesive clean, and reduces the
possibility of distorting the mat.
FIGURE 2
Lift mat and Peel Back Liner
4. Keep the mat away from the surface and
use two hands to peel back the liner a few
more inches. See FIGURE 3. Then,
continue rolling the mat, removing more
liner, and rolling until the entire mat is
applied.
5. Remove the tape hinge. Roll the top edge.
6. If needed, such as for feed-through
locations, you can modify the form or fit the
Light Mat. See Cutting the Light Mat,
above, for important instructions.
7. Repeat the above steps for any remaining
Light Mat kit components.
8. If the light mat is cut or damaged during
installation seal the perimeter non
conductive caulk. See Perimeter Caulking,
above, for important instructions.
Note:
Wiring
Other attachment systems may be used. Example: the Light Mat can be applied to a
plastic base plate and the plastic attached to the cabinet by screws or hook and loop.
Attach the wires to the LED power supply, matching the labels on mating parts. Refer to the
Wiring Diagram.
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Wiring Diagram
FIGURE 3
Use Two Hands to Remove Liner
Ensure that the sign box has a proper earth ground.
Do not alter the length of the wires.
When illuminated, the wires will not be visible inside the light box. However, if
desired, the wires may be covered by 3M™ Light Enhancement Film 3635-100
(purchase separately).
Line
+V
Neutral
Class 2
Power Supply
Ground
120 VAC
Line: Black
Neutral: White
Ground: Green, if present
3M™ Light Mat Series
3635-1000
DC Gnd
Connectors
Class 2 Output:
+V: Red
DC Gnd: Black
Consult power supply manufacturers installation instructions for connection of power
supplies. Auto ranging power supplies are marked 120-277 VAC or 120-240VAC.
Removal of Light Mat
The Light Mat cannot be reused after removing it from an application surface. Applying heat
to the Light Mat may aid in removal.
Installation Bulletin 3635-1000 - 6
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Storage and Shelf Life
Up to 2 years in original shipping container stored at 40° to 100°F (4° to 38°C) in a clean dry
area.
Troubleshooting
Problem
Possible Solution
Light Mat will not
illuminate
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Lights are blinking
• Check for excessive loading of power supply
• If the light mat was cut after receipt from 3M, check for shorts
between the two circuits
Check for proper wiring of power supply connections
Check voltage at power supply input
Check voltage at power supply outputs
Check for proper wiring of panel connections
Check voltage at panel connections
If the light mat was cut after receipt from 3M, check for shorts
between the two circuits
Warranty and Limited
Remedy
The information contained and techniques described herein are believed to be reliable, but
3M makes no warranties, express or implied, including but not limited to any implied warranty
of merchantability or fitness for a particular purpose. 3M shall not be liable for any loss or
damages, whether direct, indirect, special, incidental or consequential, in any way related to
the techniques or information described herein. Therefore, release of this document is
contingent upon successful completion of the FCC testing.
FCC Rules, Part 15
Compliance
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 a
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 their own expense.
3M Related Literature
Before starting any job, be sure you have the most current Product and Instruction
Bulletins.
The information in 3M Product and Instruction Bulletins is subject to change. Current Bulletins are
available at 3Mgraphics.com. The following applicable Bulletins provide information and processes you
need to properly make the mats described in this Bulletin. Additional Bulletins may be needed as indic­
ated in the 3M Related Literature section of other 3M components you use.
Bulletin types: PB = Product Bulletin; PB-IB = Product & Instruction Bulletin; IB = Instruction Bulletin
Subject
Type
Bulletin No.
3M™ Light Mat 3635-1000
PB
3635-1000
3M™ Light Enhancement Film 3635-100
PB
3635-100
3M Light Management Films
-3Mt Blockout Films 3635-20B, 3635-22B
-3Mt Diffuser Films 3635-30, 3635-70
-3Mt Day/Night Films 3635-91
PB
3635
3M Graphics Market Center Warranty Brochure
go to www.3Mgraphics.com, Warranties
3M is a trademark of 3M Company.
Installation Bulletin 3635-1000 - 7
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Bulletin Change Summary
Release B: Clarified 3M product numbering scheme. Updated Warnings on Pages 1 and 3. Added an
Electrical Rating table to page 2. Added information regarding Power Supplies and moved section to
page 3. updated information in Wiring Diagram on page 5. Added FCC compliance information to page
5.
Release C: Information was added about using the ferrite that is supplied with Advance Power
Supply LEDINTA0024V41FO. The section titled Power Supplies has been expanded to include
UL required information.
Release D: Added more detail regarding UL recognized components in regards to retrofitting
and power supplies.
Light Management Solutions from Commercial Graphics Division
3M Center, Building 220-12E-04
PO Box 33220
St. Paul, MN 55144-3220 USA
Technical Info. 1-800-328-3908
www.3Mgraphics.com/lighting
E3M 2010. All rights reserved.
Installation Bulletin 3635-1000 - 8