Unit 5

UNIT 5
Sign Related Electrical Components
Rationale
Why is it important to learn about sign related components?
Some electrical components that are used in conjunction with signs are
unique to the sign industry This module will include the basic theory of
operation for various types of lighting, from incandescent and neon to LED
technology; it will include the use of transformers and other neon supplies,
ballasts and power supplies relating to the sign industry; and lastly, it will
provide techniques for the installation and troubleshooting of transformers.
Outcome
When you have completed this module you will be able to:
Explain the general theory of operation of transformers.

Describe the method of operation for light sources used in the sign
industry.
Describe the installation of special application transformers used in the
sign industry.
Unit 5: Sign Related Electrical Components Page 84

5-1 TRANSFORMERS - THEORY OF OPERATION
A transformer is an alternating current device that is used to transfer

electrical energy from one ac circuit to another ac circuit.
input output
Transformer
voltage voltage
Figure 5.1
It receives energy (voltage and current) at its input and delivers energy
(voltage and current) from its output. This transfer usually involves a change
in voltage. As an example, a neon transformer may have 120 volts at the
input and 15000 volts at the output.
Method of Operation
The transfer of energy is accomplished by mutual induction.

Remember that induction, as discussed in Unit 1, is the process of generating
a voltage by moving a conductor or coil through a magnetic field. A voltage
can also be induced if the wire is held still and the magnetic field changes.
This is the method used by a transformer. A transformer is constructed by
placing two coils on the same steel core so that their magnetic fields react with
each other.
source input output load

voltage winding winding voltage
Figure 5-2

When an ac source voltage is applied to the input winding, current flows
in the winding and a magnetic field is established. Since the source voltage is
ac, the magnetic field is constantly changing in intensity and direction. The
changing magnetic field reacts with the output winding which results in a
voltage being induced into it. This induced voltage is the output voltage that
is supplied to the load.
The amount of change in voltage between the input and the output of a
transformer depends upon the number of turns of wire on the input winding
compared to the output winding. As an example, if the output winding has
two times as many turns as the input, then the output voltage will be two times
the input voltage.
Transformer Terminology
Primary: the winding that is connected to the source.
Secondary: the winding that is connected to the load.
High-voltage winding: the winding that is connected to the highest

voltage. It could be either the primary or the secondary.
Low-voltage winding: the winding that is connected to the lowest

voltage. It could be either the primary or the secondary.
Step-up transformer:
input voltage Step-up output voltage
Is a type of transformer = 120 V Transformer = 5000 V
connection where the

secondary or load voltage is
higher than the primary
voltage.
Step-down transformer:
input voltage Step-down output voltage
Is a type of transformer = 240 V Transformer = 120 V
connection where the primary

or supply voltage is higher Figure 5-3
than the secondary voltage.

Note that the same transformer could be used as either a step-up or a
step-down.
Transformer Ratings
The power rating of a transformer refers to the amount of power that it

can handle. As an example, a 450 VA transformer is capable of supplying
450 VA to a load.
primary
voltage
neon
= 120 V
transformer
secondary voltage = 15000 V
neon tubing
Figure 5-4
This means that if the neon transformer, shown in Figure 5-4, is

handling 450 VA as it is supplying a 15000 V neon tubing load from a 120 V
supply, the currents in the primary and secondary could be calculated as
shown below. It is important to be able to calculate the primary current of a
transformer. As mentioned previously, a conductor feeding a neon sign
transformer cannot be loaded to more than 80 % of its capacity. A #14 AWG
conductor protected by a 15 A circuit breaker cannot be loaded more than 12
A.
Primary current= 450 VA ÷ 120

V Secondary current= 450 VA ÷
= 3.75 A 15000 V
= 0.030 A or 30 mA
_______________________________________________________________
_________
There could be only three of these transformers on one circuit. Four
transformers would load up the circuit to more than 12 A.
3 x 3.73 A = 11.25 A 4 x 3.75 = 15 A
Electronic Neon Transformers
Electronic neon transformers operate on a slightly different principle

than conventional mutual induction transformers. Using electronic circuits,
the incoming 60 Hz ac voltage is converted to dc; the dc voltage is then
changed back to a high frequency ac voltage (about 20,000 Hz); and lastly, the
high frequency ac voltage is fed through a step-up transformer to produce a
high voltage.
generates
input changes high step-up output
ac to dc frequency transformer
120 V, 60 Hz. 9000 V, 20 kHz
ac
Electronic Transformer
Figure 5-5
The design of the neon electronic transformer is based on the principles
that at high frequencies:
- neon tubes light much easier; and
- induction transformers can be made smaller and lighter.
As a result, the main advantage for using an electronic transformer is its

reduced weight and size compared to conventional transformers. Additional
advantages, depending on the manufacturer, may include:
- an output voltage that can be adjusted within a range of about 2000 V
to 10000 V;
- a dc voltage input option; and
- open circuit protection where the circuit is shut down if a tube is
broken.
The main disadvantages include:

- the initial cost and - the extra care and attention that is required when
installing the tubes and related wiring. The high operating frequency requires
that the spacing of the tubes and wiring be more carefully planned.

5-2 LIGHT SOURCES USED FOR SIGNS
There are many types of light sources available for signs. However,
there are some general groups of light sources that have similar operating
characteristics. We will briefly discuss each of these groups of light sources,
identify how each produce light, and consider the advantages and
disadvantages of each type.
Incandescent Lighting
An electric current passing through a filament (high resistance wire)

causes it to get extremely hot and as a result, it gives off light. The light given
off is called incandescent.
light
filament
current
light
Figure 5-6
The filament is enclosed in a glass bulb to prevent the hot filament from
coming in contact with oxygen and burning up.
The main disadvantage of the incandescent lamp is that it has a low

efficiency rating; it has a low light energy output compared to the amount of
electrical energy it consumes. However, the low initial cost continues to make
it a popular choice for many applications. Other types of light sources have
long-term advantages over the incandescent lamp.
Fluorescent Lighting

The fluorescent tube falls in the general category of low-pressure
discharge lamps. It operates on the principle of a current passing through a
vapour or gas rather than a high resistance wire.
Figure 5-7
The tube is filled with low-pressure argon gas which ionizes (takes on an
electric charge) and allows current to flow when sufficient voltage is applied
to the ends of the tube. In addition to the argon gas, there are small amounts
of mercury placed in the tube. Current enters the tube through the contact pins
located on the ends of the tube. As the electrons travel from one end of the
tube to the other, they collide with mercury atoms; these collisions release
ultraviolet energy (light that is not visible to the naked eye). The phosphor
coating on the inside of the tube reacts to the ultraviolet energy and turns this
energy into visible light.
This process requires a special application transformer; a ballast, which

has two functions:
1. it provides the high voltage (about 500 V) required to move

current through the tube before the gas heats up;
2. it limits the amount of current flowing in the tube after the
gas in the tube has heated up.
The impedance of the gas in the tube is high initially; it decreases as

current begins to flow and as the gas heats up. With the impedance
decreasing, the current would increase to a value that could damage the tube if
the ballast did not have characteristics that limit the current in the circuit.

Fluorescent lighting has many advantages over standard incandescent
lamps.
Fluorescent lamps have a life expectancy approximately 20 times as

long as standard incandescent lamps. As a result, maintenance costs are much
lower, because the fluorescent lamps do not have to be replaced as often. The
higher initial cost of fluorescent lighting is more than offset by its long life.
Fluorescent lighting is more efficient than standard incandescent

lighting.
light output
40 W, 48 inch 150 W standard

flourescent incandescent
Figure 5-8
As a result of the increased efficiency, fluorescent tubes produce less

heat than incandescent bulbs of the same size. This may be an advantage in
that they do not place a large heat load on the air conditioning system when
installed inside a building.
The main disadvantage of fluorescent lighting is that the colour of the

light produced by standard tubes is not "full spectrum". The light tends to be
higher in the blue/green end and lower in the red/yellow end of the spectrum.
This may distort the colour of objects being lighted by fluorescent fixtures.
The first fluorescent lamps were preheat lamps. A few of these lamps
are still used as inexpensive desk lamps where you are required to hold down
a switch for a few seconds and the lamp comes on when the button is released.
As you hold the button down, the ends of the tube are being preheated so that
electrons are released. When the switch is released a high voltage is applied to
the lamp causing current to flow and the lamp to turn on. Many of the fixtures
used a means of automatically preheating the tubes called a starter. This style
of lamp is largely obsolete and being replaced with instant start or rapid
start type lamps.

Instant start lamps were developed so that the preheating process could
be eliminated. It uses a sufficiently high voltage across the tube to break
down the impedance of the tube and strike an arc. Because no preheating is
required with instant start lamps, only a single pin at each of the tube is
necessary. One style of these lamps is called "slimline". You should be aware
that a few instant start lamps use a bipin base; however, they cannot be used
with preheat or rapid start circuits.
Rapid start lamps also start quickly without a preheating process and
utilize a much smaller and more efficient ballast than that required by instant
start tubes. The rapid start fixture uses a cathode that can be
heated continuously. This allows the fluorescent lamp to be used in
applications that were previously not possible - dimming, flashing, high
output and low temperature operation. Fluorescent lamps rated as high
output, very high output and outdoor (low temperature) operate on the same
rapid start principle but are equipped with ballasts capable of supplying much
more current.
Some fluorescent lamp ballasts are equipped with thermal protection.

This is typically an internal, inaccessible device designed to disconnect the
ballast from the circuit if the temperature of the ballast becomes dangerously
high. These dangerous conditions are normally a result of a short circuit in
the ballast windings and the ballast must be replaced.

Lamp coloring
Fluorescent lamps are available in several shades of white. These shades used
to have names like warm white and cool white, but now the colors are rated in
Kelvin (K). Typical incandescent lighting is 2700 K, which is yellowish-
white. Halogen lighting is 3000 K. Fluorescent lamps are manufactured to a
chosen color by altering the mixture of phosphors inside the tube. Warm-
white fluorescents are 2700 K and are popular for residential lighting. Neutral-
white fluorescents have a color of 3000 K or 3500 K. Cool-white fluorescents
have a rating of 4100 K and are popular for office lighting. Daylight
fluorescents have a Kelvin rating of 5000 K to 6500 K, which is bluish-white.
These are popular for signs with white lettering.
LED Lighting
A light-emitting diode (LED) is made of semiconducting material and is one

of the newest innovations in light sources for signs. LEDs have been used as
indicator lamps in many devices because of the low-intensity light that they
emit. LEDs present many advantages over other light sources including more
efficient use of energy, longer lifespan, improved reliability, smaller size,
faster switching, and greater durability. Solid state devices such as LEDs will
last for a long time if operated at low currents and at low temperatures. Many
of the LEDs produced in the 1970s and 1980s are still in service today.
New LED technology has made them more practical and they are available in
many shapes, colors and intensities. Energy provided for this type of
installation must be limited to low voltage DC and will require a rectifier and
transformer to supply power. Some more advanced units may also require a
controller that will energize only certain sections or a single unit of LED.
These are usually placed in message center signs that could include multiple
LEDs of different colors and intensities to form a new color. Generally the
new colors produced will be a combination of the primary colors of red, blue
and green or as labeled on the controller (R,G,B)

Epoxy Lens
Flat spot
indicates the
Cathode side
of the LED
Anode + Cathode -
When a light-emitting diode is forward biased (switched on), electrons are

able to recombine with holes within the device, releasing energy in the form
of photons. The colour of the light (corresponding to the energy of the photon)
is determined by the energy gap of the semiconductor. To switch a diode “on”
the polarity of the power supply is extremely important. Positive “+” must be
applied to the Anode side and negative “-must be on cathode side. Voltage
must not exceed the maximum value. If the maximum voltage rating is
exceeded by even a small amount, the current rating may be exceeded by a
large amount, potentially damaging or destroying the LED.
Like other lighting devices, LED performance is temperature dependent. Most

manufacturers’ published ratings of LEDs are for an operating temperature of
25°C. Higher temperatures within the light can result in reduced light output
or even lamp failure.
LEDs maintain consistent light output even in cold temperatures, unlike

traditional lighting methods. Because LEDs do not generate as much heat as
incandescent bulbs, they are considered to be an energy-efficient technology.
On the other hand, because they do not generate much heat, ice and snow may
build up on the LED lamp in colder climates.

Power Supplies
Power supplies for LED ‘s must be matched to the LED used, voltage must
not exceed the rated value, the voltage must be converted to a DC supply and
the current must be limited to not exceed the rated power of the unit. The
typical solution is to use constant power supplies, or to drive the LED at a
voltage much below the maximum rating. Since most power sources are not
constant current sources, most LED fixtures must include a power converter.
As with all diodes, current flows easily from p-type to n-type material.
However, no current flows and no light is produced if a small voltage is
applied in the reverse direction. If the reverse voltage becomes large enough
to exceed the breakdown voltage (VRRM), a large current flows and the LED
may be damaged.
LED styles available
LEDs are available in several styles
1. Module style. These are smaller sections of LED that can be fashioned
to any style or shape required. Care must be taken to not exceed the
power rating of the DC power supply.

2. RGB system used for multiple color signs programmable signs. This
type of LED requires a controller to control the intensity of each of the
primary colors: Red, Green, and Blue.
3. Linear systems may include a heat sink, printed circuit board, several
LED’s, a power supply housing, a flexible electrical connector, a
second electrical conductor and a power supply.
4. Flexible border LED tubing can be used as a alternative to neon

border tubing and is becoming increasingly popular with the move to
low-voltage, energy efficient lighting. It is available in several bright
colors such as white, blue, green, yellow, orange, and red. It can be
bent to radiuses of small as 4 inches. However they must be bent on
the plane that they are designed to flex on and can be easily broken if
forced to a shape they are not designed for. Mounting clips,
connectors, jumpers, and several available lengths make this product
extremely versatile.

RGB systems
The main types of LEDs are miniature, high power devices and custom
designs such as alphanumeric or multi-color.
• Tri-color LEDs are two LEDs in one case, but the two LEDs are
connected to separate leads so that each LED can be controlled
independently and lit simultaneously. A three-lead arrangement is
typical with one common lead (anode or cathode).
• RGB LEDs contain red, green and blue emitters, generally using a
four-wire connection with one common lead (anode or cathode). These
LEDs can have either common positive or common negative leads.
Others however, have only two leads (positive and negative) and have
a built in tiny electronic control unit.
Neon Lighting
Neon lighting is also classified as low-pressure discharge lighting or

high-voltage luminous discharge lighting. It is similar in operation to
fluorescent tubes, but because the efficiency of neon lighting is less that of
fluorescent lighting, neon is not used as a source of light for illumination of
large areas. However, the long tubes provide tremendous versatility when
used for advertising signs.
Figure 5-9

The materials used in the construction of the tube determine the color of
the light. Neon tubes are made in three basic varieties:
-when the tube is filled with pure neon, it gives off a

red light;
-when the tube is filled with a mixture of argon and

mercury, it gives off a blue light; and
-when the tube is filled with a mixture of argon and

mercury plus a phosphor on the inner wall of the tube, it
will give off a variety of colors depending on the
phosphor used.
Argon gas filled glass is the only type that is susceptible to cold temperatures.
Neon signs are operated from transformers that have secondary output
voltages of several thousand volts. The operating voltages are high because
the neon tubing can be several meters in length, have a small diameter (10-20
mm), and have a cold cathode.
The impedance of the tubes changes as the length of the tube changes
and as the diameter of the tube changes.
↑ length of the tube ⇒ ↑ impedance ⇒ ↓ current flow
Therefore, for a longer tube, a transformer that has a higher voltage must be
used to maintain the same light intensity.
↑ diameter of the tube ⇒ ↓ intensity of light ⇒ ↓ impedance ⇒ ↑

current flow
Therefore, for a larger diameter tube, a transformer that has a lower voltage
should be used to maintain the same light intensity.
The shape of the tube is seldom straight and is usually tailor-made to the
customer's wishes. The person shaping the tube must be very careful not to let
the diameter of the tube change while shaping the tube. Any decrease in the
diameter will change the impedance.

High-Intensity Discharge (HID) Lighting
The term high-intensity discharge describes a wide variety of lamps that

produce light from a gaseous discharge tube/bulb, similar to a fluorescent, but
operating at a higher pressure. They can be divided into three main
categories:
- Mercury Vapour.
- Metal Halide.
- High Pressure Sodium.
The operation of mercury vapour lamps and metal halide lamps is

similar. Both require the use of a ballast to provide the high voltage necessary
to start current flow in the lamps and limit the flow of current after the gas in
the tube has ionized. However, they differ slightly with regard to operating
efficiency and light characteristics.
The main advantage of mercury vapour is that it has an average life

expectancy of more than 16000 hours. This makes it an ideal light source
where relamping is costly. Metal halide, on the other hand, has a slightly
shorter average life expectancy than mercury vapour but has the capability to
produce about 50% more light with improved colour characteristics.
High-pressure sodium lamps use a different type of ballast than mercury

vapour or metal halide. The ballast produces a high voltage pulse similar to
the electronic transformer until the arc has been established. The main
advantage of high-pressure sodium lamps is that they produce about 50%
more light than other HID lamps of similar wattage ratings.

Disposal of fluorescent and HID lamps
Fluorescent bulbs are both an environmental and a waste management issue so

diverting fluorescent bulbs from landfills to other end-of-life management is
extremely important. Since fluorescent lamps contain mercury there may be
an extra cost to disposal for both residential and commercial applications.
While the disposal of fluorescent bulbs is an issue it is important to note that
the use and disposal of mercury-containing lamps still is more
environmentally more responsible than the use of incandescent bulbs.
Incandescent bulbs consume significantly more energy than fluorescent bulbs,
so they result in greater mercury emissions over the lifecycle of the bulbs.
Lamp manufacturers are working to reduce the mercury content of

fluorescent lamps to the minimum amount feasible without reducing lamp life.
These lamps normally have identifying marks to identify them. Usually the
metal ends of the lamps are green in color. Manufacturers are trying to
produce fluorescent lamps using xenon or phosphor and plasma; however,
efficiencies have become a factor.
As of June 2005 a Canada Wide Standard for lamps containing mercury was
published. Using 1990 as a baseline, the report recommended a numeric
target of 70% by 2005 and a total reduction of 80% by 2010. Individual
jurisdictions plans can be found on Environment Canada’s website or in each
provinces environment websites.
5-3 TRANSFORMERS - INSTALLATION AND APPLICATION
Although the basic operation of transformers used in the sign industry is

the same as transformers used in other industries, there are some installations
and applications that are unique to sign lighting. This is especially true for
neon sign transformers. This section will consider some of these applications.

Standard Ratings
The ratings of neon sign transformers may vary from one manufacturer
to another, however, there are typical values which seem to remain consistent
throughout the industry.
Ratings: Typical values:
Primary voltage 120 V; 277 V
Secondary voltage 15,000 V; 12,000 V; 9,000 V; 7,500 V;

6,000 V; 5,000 V; 4,000 V; 3,000 V;
Secondary current 120 mA; 60 mA; 30 mA; 20 mA
Capacity in volt-amperes values between 100 VA and 900 VA
Power factor normal; high
Note that some unique application transformers such as "Cold Cathode

Transformers" may have ratings that differ from those listed above.
Power Factor
Power factor (p.f.) is used to describe the phase relationship between the
current and voltage in an ac circuit. If the current changes at the same time
and in the same direction as the voltage, the current is said to be in phase with
the voltage. If the current and voltage do not change together, as is the case
with circuits that contain inductance and capacitance, they are said to be out
of phase.
The power factor for a circuit where the current and voltage are in-phase
is considered to be a high power factor. As an example, a circuit that
contained only incandescent lighting would have a high power factor.
The power factor for a circuit where the current and voltage are out of
phase is considered to have a low or poor power factor. The actual power
factor will vary, depending on how much the current and voltage are out of
phase. Transformers operate on the principle of inductance and may have a
low power factor.

Referring to Figure 5-10, the power factor is the ratio of power used to
light neon compared to power supplied. The utility supplies power to the
transformer. The transformer uses power to light the neon. Some power is
used inside the transformer to create the magnetic fields necessary to step up
the voltage.
With a high power factor, the transformer uses less power inside. The
same power is available to light the neon, but the utility does not have to
supply as much power, see
Figure 5-11.
Low Power Factor
With less power

V.A.
supplied, the customer's
Power Used Inside
monthly electric bill will Power Supplied the Transformer
be lower. p.f.
Watts
Power Used to Light Neon
The power factor of a circuit can Figure 5-10

have an impact on the cost of the energy
required to operate the circuit. As an example, for the same amount of output
power a neon transformer with a low power factor will draw more current
than a transformer with a high power
High Power Factor
factor. This applies to the entire time that
V.A.
the transformer is operating: as a result Power Supplied
Power Used Inside
low-power-factor transformers not only the transformer
Watts
require additional current, but may also Power Used to Light Neon
need heavier wire and have higher
Figure 5-11
installation costs. The number of low-power-
factor transformers that can be put on a circuit
will be lower than if high-power-factor transformers are used. This is because
the low-power-factor transformers require more current and the circuit current
is limited to 12 A.

The power factor of a circuit can be corrected by adding components
that change the amount that the current and voltage are out of phase. A
capacitor connected in parallel with the primary of a transformer can improve
the power factor.
Recently, as more efforts are made to conserve energy, manufacturers

of transformers used in the sign lighting industry are constructing transformers
so that they have a high power factor.
Nameplate Information
There is standard information about the transformer provided by the
manufacturer on the transformer nameplate. Typically, it will include:
Manufacturer's name; i.e. Allanson, Phillips etc.
Name of the equipment; i.e. luminous tube transformer
Where it was made; i.e. Made in Canada.
Primary voltage; usually 120 V or 277 V
Primary frequency; operating frequency ; 60 Hz in Canada
Primary VA; input power, i.e. 135 VA
Secondary voltage; output voltage between the high voltage

terminals; i.e. 9000 V or 12000 V
Secondary current; loaded output current; i.e. 30 mA
Power factor (p.f.) high, if elements have been added to the

transformer to change the operating
power factor; otherwise p.f. is normal.
Type No. information regarding type of enclosure,

size of enclosure etc. i.e. Allanson
#458B
Cat. No. Manufacturer's part number to be used
when ordering replacements. i.e.
Jefferson # 721-141

Approval; approved for use in Canada (CSA, ULc,
Warnock- Hersey) and/or the United
States (UL)
May also indicate if it is a "mid point grounded"; or "balanced" type.

Secondary Connections
There are two ways that the neon tubing can be connected to the
transformer: between the high-voltage output terminals; and between each of
the high-voltage output terminals and the mid-point ground.
Figure 5-12 shows an

installation where the neon tubing 120 V neon
is connected as two circuits. The transformer
GTO
loads are in parallel and each
neon tubing neon tubing
circuit is supplied from one of the
high-voltage terminals and the
mid-point ground of the
Figure 5-12
transformer. This method is used
in order to reduce the length of
high-voltage cable (GTO), that is
at the high potential. The cable
connected to the mid-point of the
transformer is at ground potential.
Figure 5-13 shows an 120 V neon

installation where the neon tubing transformer
GTO
is connected as one circuit. The
neon tubing neon tubing
loads are connected in series and
each circuit is supplied from both
high-voltage terminals of the Figure 5-13
transformer. In this case the GTO
cable between the loads is at or
near ground potential if the loads
have similar impedance.

Neon Transformer Loading
Neon transformers differ from other types of transformers in that they

can operate with the high-voltage secondary terminals short circuited. If the
secondary of a standard distribution transformer was short circuited, a very
high current would flow because the load impedance under short circuit
conditions is effectively zero ohms. A neon transformer, however, is designed
with an internal impedance that will limit the secondary current under short
circuit conditions.
A neon transformer will operate most effectively at about 80% of its

rated short circuit current. As an example, a transformer that has a rated short
circuit current of 120 mA should ideally be operated at 96 mA for optimum
efficiency.
120 mA x .80 = 96 mA
Since some variations in tube length, temperature, and line voltage are
usually present, some manufacturers recommend an optimum range of:
77.5% to 82.5% for indoor or outdoor enclosed; and

82.5% to 85% for cold weather - mercury filled
tubes.
The following chart lists the most common secondary current ratings
and the approximate ranges of secondary current for effective operation of an
indoor or outdoor enclosed neon transformer.
Rated secondary mA Ideal value Effective range

(mA x .80) (mA x .775 ) to (mA x
.825)
120 96 93 to 99
60 48 46.5 to 49.5
30 24 23.3 to 24.8
20 16 15.5 to 16.5

To determine the operating conditions, the secondary current values of a
neon transformer can be measured using an ac mA meter such as the
"TRANSCO AC MILLIAMMETER". Use the following procedure to
determine if the loading on the transformer is within the recommended range:
1. Turn the power off and disconnect the high-voltage leads.
2. Measure the short circuit current of the transformer by connecting

the mA meter as shown in Figure 5-14 and turning the power on.
120 V neon
transformer
mA
Figure 5-14
The value of the measured secondary current should be within about

10% of the rated secondary current on the nameplate of the
transformer. Changes in primary supply voltage will result in
changes in the transformer output.
3. Turn the power off and reconnect a length of neon tubing and the
mA in series with the secondary of the transformer as shown in
Figure 5-15.
120 V neon
transformer
neon tubing mA
Figure 5-15
With the power turned on, the mA reading should be within the
ranges indicated in the chart shown above if the transformer and the
tubing load are matched. In some cases, the mA reading may be
outside the ranges indicated in the chart:

Below range
If the value is below the range recommended the transformer is

overloaded and a higher voltage transformer should be tried (in
this situation the neon would probably flicker).
Above range
If the value is above the range recommended the transformer is

under loaded and a lower voltage transformer should be tried (in
this situation the transformer would be producing more heat than
normal due to the increase in current).
If the transformer loading is outside the current in the chart, the sign
may not have trouble-free operation. The manufacturers have footage charts to
help determine transformer loading; however, improper pressurizing or bends
that reduce the tube diameter can change the tube's impedance, leading to
trouble. High-voltage leads that are beyond the recommended length will put
extra loading on the transformer. Taking a current reading under load and
under short circuit conditions will help determine if the transformer is
operating within the manufacturer's recommendations. The following is an
example of what one may find when taking this test.
Example:
A neon sign has had problems in the past and you are sent to fix the
sign. All tubes are lit when a load test was performed on the sign. The
following data was obtained.
Name plate data 12,000 V

30 mA
Short circuit current (only the milliammeter in the circuit)
30 mA
Load current (neon in circuit)
28 mA
Since the short circuit current is the same as the nameplate current, the
transformer is okay. The load current is above the value in the chart. For
trouble-free operation this transformer should operate around 24 mA. Since
the sign is already made adding neon to increase the loading is not an option.
One probable solution is to reduce the size of the transformer to a 9000 V, 30
mA. Another load test can be done to see if the new transformer is properly
loaded.

Primary Voltage
The measurement of the primary should be within 5% of the rated voltage of

the ballast. For example if the rated voltage of the transformer is 120 V a
measured voltage of 125 V to 115 V would be considered acceptable. If the
measured voltage is extremely low then there must be a loss of voltage ahead
of the transformer. If the voltage is less than 115 V then an electrician should
be called to repair the primary power supply.
Fluorescent light troubleshooting
Refer to above Figure
Given a ballast with multiple wiring combinations, if you do not plan to use
the maximum number of lamps on the nameplate, ensure any ballast lead
wires are properly insulated from each other and the ground. The electrical
tape, if used, must be at least as thick as the original wire insulation.
Primary Current
To check the primary current with your digital ammeter, clip your meter
around the black or white lead on the ballast. This measurement should be the
same as, or less than, the label on the ballast. If this is a high output
fluorescent and the tube length is not at the maximum, this measured current
will be less than the nameplate information. If the current is more than the
rated value there could be a short in the ballast or the ballast may be
incorrectly installed. Please refer to the wiring diagram on the ballast before
replacing the ballast.
Primary Voltage
To check the primary voltage with a digital voltmeter place one of the meter
leads on the black conductor of the ballast and the other lead on the white
conductor of the ballast. Make sure that you have the meter set to AC voltage.
The measurement of the primary should be within 5% of the rated voltage of
the ballast. For example if the rated voltage of the ballast is 120 V, a
measured voltage of 115 V to 125 V would be considered acceptable. If the
measured voltage is extremely low then there must be a loss of voltage ahead
of the ballast.
1. Check for sign disconnect switch position

2. Check circuit breaker or fuse and reset
3. Measure with your digital volt meter between the black
conductor on the ballast and the green bond or sign metal
frame. If it reads the rated voltage then the white conductor
likely has a poor connection.
Filament current
Measure the current in one of the colored conductors that attach to the lamps
(not the black or white primary leads). A normal reading would be between
0.5 A and 2 A. Values above or below this current could indicate a damaged
or defective ballast.
Current below 0.5 A could indicate an open lamp filament, a damaged lamp
holder (tombstone) or a low primary voltage to the ballast.
Current above 2 A could indicate a short circuit in the lamp filament, a short
through a lamp holder (tombstone) or that the primary voltage is higher than
rated.
Filament resistance
Using your digital meter adjust the meter into the ohms setting. Remove the
fluorescent lamp and measure from pin to pin on the lamp. This test is done
on one side of the lamp and then the other side of the lamp. A measurement
of 0.5 ohms to 1.2 ohms is considered normal. A resistance greater than 1.2
ohms indicates an open filament and the lamp should be replaced. A
resistance under 0.5 ohms indicates a shorted filament and the lamp should be
replaced. Near the end of the lamp’s useful lifespan filaments tend to fail and
the ends of the lamps tend to blacken.

Open circuit voltage check
An open circuit check can be performed on a ballast. This however is quite a

dangerous test. The voltages are measured on the secondary of the ballast and
can be from 500 V to 1000 V. Please consult the ballast manufacturer and
your meter manufacturer before performing this test. If the voltage exceeds
the maximum voltage of your meter, your meter may explode in your hands.
Lamp current
Lamp current can also be measured if your clip on ammeter is clamped around
the lamp itself. Readings of 0.4 A to 0.8 A are considered normal. If the
reading is less than 0.4 A on a lamp the total footage of the lamp may be
exceeded, there could be a lamp with an open filament or the ballast may be
damaged. Current of 0.8 A or above would indicate a total lamp footage
under the minimum amount, or a lamp with shorted filaments.
LED troubleshooting
Input Current of DC power supply
To check the input current with your digital ammeter, clip your meter around
the black or white lead on the dc power supply The meter should be set to
measure AC current. This measurement should be the same as, or less than,
the label on the input current of the DC power supply. A 12 W output should
have an input current of about 0.14 A if attached to a 120 V AC supply. The
larger the wattage of the dc power supply, the larger the required input
current. The input current should not exceed the maximum input current.
Input Voltage of DC power supply
To check the input voltage with a digital voltmeter place your meter leads on
the terminals that say “Input Voltage”. Make sure that you have the meter set
to AC voltage. The measurement of the primary should be within 5% of the
rated voltage of the power supply.
Output current
Set the meter to measure DC current. Measure one of the two output
conductors by clipping on to one conductor.E The output current should not
exceed the rated value of current of DC output. For example a 12 W DC
power supply with an output of 12 V DC should have a maximum current of 1
A. A power supply with a higher power rating will have a higher current
output. If the output current is 0 A and the primary voltage is the expected
reading replace the DC power supply.

Output Voltage
When using your digital meter to measure the DC output voltage take care to
observe the polarity of the output terminals. If the DC supply has the wrong
polarity the LED will not light and could become damaged. If the output
voltage of the DC supply is less than the rated voltage the LED may light but
will be dimmer than usual. If the output voltage is the same as the rated input
voltage the DC supply is damaged and should be replaced.
LED Advantages
• Efficiency: LEDs produce more light per watt than incandescent

bulbs.
• Color: LEDs can emit light with an intended color without the use of
the color filters
• Size: LEDs can be very small
• On/Off time: LEDs light up very quickly.
• Cycling: LEDs are ideal for use in applications that are subject to
frequent on-off cycling, unlike fluorescent lamps that burn out more
quickly when cycled frequently,
• Dimming: LEDs can very easily be dimmed either by pulse-width
modulation or lowering the forward current.
• Cool light: In contrast to most light sources, LEDs radiate very little
heat.
• Slow failure: LEDs mostly fail by dimming over time, rather than the
abrupt burn-out of incandescent bulbs.
• Lifetime: LEDs can have a relatively long useful life of 35,000 to
50,000 hours
• Focus: The solid package of the LED can be designed to focus its
light. Incandescent and fluorescent sources often require an external
reflector to collect light and direct it in a usable manner.
• Toxicity: LEDs do not contain mercury
LED Disadvantages
• High initial price: LEDs are currently relatively expensive.

• Temperature dependence: LED performance largely depends on the
ambient temperature of the operating environment. Operating the LED
in high ambient temperatures may result in overheating of the LED
package, eventually leading to device failure.
• Voltage sensitivity: LEDs must be supplied with the voltage above
the threshold and a current below the maximum rating. This can
involve series resistors or current-regulated power supplies.
• Light quality: The color rendering properties of common fluorescent
lamps are often inferior to what is now available in state-of-art white
LEDs.
• Light pollution: Cool-white LEDs can cause more light pollution than
other light sources
UNIT 5 SUMMARY
• A transformer is device used to transfer electrical energy from one

circuit to another.
• Transformers operate on the principle of mutual induction; the magnetic

field of the primary winding reacts with the secondary winding.

• The primary is connected to the source.
• The secondary is connected to the load.
• A step-up transformer has a low voltage on the primary and a high

voltage on the secondary.
• Electronic transformers can be made lighter and smaller because they

operate at a high frequency.
• Incandescent lights give off light when a current passing through a high
resistance wire causes the wire to get white hot.
• Fluorescent light is produced when current passes through a low-

pressure gas which results in ultraviolet energy bombarding the
phosphor coating on the inside of the tube.
• Fluorescent lighting is more efficient than incandescent lighting.
• Luminous discharge lighting (neon) operates similar to fluorescent but

requires a higher voltage to cause current to flow.
• High-intensity discharge lighting operates at high-voltage and high-

pressure.
• All gas tube lighting (fluorescent, luminous discharge and high-intensity

discharge) requires a ballast or transformer to: a) provide a high voltage
to start current flow; and b) limit (or ballast) the current after it begins
to flow.
• A high power factor transformer is desirable because it usually means

that the line current will be reduced.
• The tubing can be connected to the secondary of a neon transformer in

either series or parallel.
• Ideally, a neon transformer should be loaded to about 80% of its rated

short circuit current.

Unit 5

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Unit 5

Transféré par

Droits d'auteur :

Formats disponibles

UNIT 5

Sign Related Electrical Components

Why is it important to learn about sign related components?

Explain the general theory of operation of transformers.

Unit 5: Sign Related Electrical Components Page 84

A transformer is an alternating current device that is used to transfer

The transfer of energy is accomplished by mutual induction.

source input output load

Unit 5: Sign Related Electrical Components Page 85

Primary: the winding that is connected to the source.

Secondary: the winding that is connected to the load.

High-voltage winding: the winding that is connected to the highest

Low-voltage winding: the winding that is connected to the lowest

Is a type of transformer = 120 V Transformer = 5000 V

connection where the

Is a type of transformer = 240 V Transformer = 120 V

connection where the primary

Unit 5: Sign Related Electrical Components Page 86

The power rating of a transformer refers to the amount of power that it

This means that if the neon transformer, shown in Figure 5-4, is

Primary current= 450 VA ÷ 120

3 x 3.73 A = 11.25 A 4 x 3.75 = 15 A

Electronic Neon Transformers

Electronic neon transformers operate on a slightly different principle

As a result, the main advantage for using an electronic transformer is its

The main disadvantages include:

Unit 5: Sign Related Electrical Components Page 88

An electric current passing through a filament (high resistance wire)

The main disadvantage of the incandescent lamp is that it has a low

Unit 5: Sign Related Electrical Components Page 89

This process requires a special application transformer; a ballast, which

1. it provides the high voltage (about 500 V) required to move

The impedance of the gas in the tube is high initially; it decreases as

Unit 5: Sign Related Electrical Components Page 90

Fluorescent lamps have a life expectancy approximately 20 times as

Fluorescent lighting is more efficient than standard incandescent

40 W, 48 inch 150 W standard

As a result of the increased efficiency, fluorescent tubes produce less

The main disadvantage of fluorescent lighting is that the colour of the

Unit 5: Sign Related Electrical Components Page 91

Some fluorescent lamp ballasts are equipped with thermal protection.

Unit 5: Sign Related Electrical Components Page 92

A light-emitting diode (LED) is made of semiconducting material and is one

Unit 5: Sign Related Electrical Components Page 93

When a light-emitting diode is forward biased (switched on), electrons are

Like other lighting devices, LED performance is temperature dependent. Most

LEDs maintain consistent light output even in cold temperatures, unlike

Unit 5: Sign Related Electrical Components Page 94

LED styles available

LEDs are available in several styles

Unit 5: Sign Related Electrical Components Page 95

4. Flexible border LED tubing can be used as a alternative to neon

Unit 5: Sign Related Electrical Components Page 96

Neon lighting is also classified as low-pressure discharge lighting or

Unit 5: Sign Related Electrical Components Page 97

 -when the tube is filled with pure neon, it gives off a

 -when the tube is filled with a mixture of argon and

 -when the tube is filled with a mixture of argon and

↑ length of the tube ⇒ ↑ impedance ⇒ ↓ current flow

↑ diameter of the tube ⇒ ↓ intensity of light ⇒ ↓ impedance ⇒ ↑

Unit 5: Sign Related Electrical Components Page 98

The term high-intensity discharge describes a wide variety of lamps that

-when the tube is filled with pure neon, it gives off a

-when the tube is filled with a mixture of argon and

-when the tube is filled with a mixture of argon and