Channel Letter

Page 1 of 8
Application document for Backlight LM03A
Version: 02.08.2005
Description
Illuminated channel letter
Construction
Data sheets on:
http://www.osram.com/products/led-systems
Channel letter structure
To illuminate channel letters on buildings for interior and
exterior applications.
In a channel letter the OSRAM BACKlight LM03A
backlights the Acrylic glass with great homogeneity and
without creating shadows. The letters attract a high level
of attention as a result of the full LED colours and their
high brightness
Note: Read the OS-LM03A BACKlight product data
sheet through carefully. It contains detailed descriptions
of the main safety and installation instructions.
You should also read the OPTOTRONIC

Technical
Guide for the installation of the equipment and data
sheets OT50/220-240/10 (IP20) and OT50/120-277/10 E
(IP64).
Components of the channel letter:
a) Metal or aluminium bottom section of the letter
b) Acrylic glass with fixing bracket
c) Double base made of rigid PVC foam, for example
Kmacel
Note: The double base made of rigid foam is not
essential for the construction, but a small distance from
the acrylic reduces the required number of LED modules.
Direct contact with possible water is avoided
1.
2.
Channel Letter
Page 2 of 8
Application document for Backlight LM03A
Version: 02.08.2005
Products
Products and accessories
Mechanical connectors
Electrical connection terminals
Products and accessories used:
a) Mechanical fixing systems to secure the LED modules
To the base.
Screws (size M4)
Spacers for screwing in or gluing -
www.richcoint.com
see Appendix -1- for ordering drawings
Metal holders with threads; secure to the metal base
by spot welding
Note: The BACKlight has no metallic contact surfaces
on the rear. This also means that other connection
methods, such as gluing, are possible in principle.
However, the adhesive must not run upwards through the
installation hole. This may result in short-circuits and
destruction.
b) Electrical connection terminals
The following may be used:
Cable terminals - www.wago.com;
See ordering drawings in Appendix -2-
Wire nuts
Note: Not all terminals are equally suitable for rigid and
flexible cables. Suitable terminals for both types of cables
are listed in the appendix.
3.
a) b)
c) d)
Channel Letter
Page 3 of 8
Application document for Backlight LM03A
Version: 02.08.2005
OPTOTRONIC

50 Watt
OT50/230-240/10 (interior IP20)
OPTOTRONIC

50 Watt
OT50/120-277/10 E (exterior IP64)
BACKlight LM03A
c) Power supplies 50 Watt: OT50/230-240/10
OT50/120-277/10 E
The OT50/230-240/10 is secured to the base after
removing the cover caps.
The appliances feature the following safety functions:
Open-circuit protection
Short circuit protection
Overtemperature protection
Overload protection
The appliance operates on a SELV basis. The primary
and secondary sides are electrically isolated. All the
contacts on the secondary side can be touched without
danger.
Note: Only the OT50/120-277/10 E appliance can be
connected in parallel.
d) BACKlight LM03A
1 chain consists of 8 individual circuit boards connected
with flexible cables. The overall length of the chain is
550 mm at maximum extension. The module can be
separated at any point between the individual circuit
boards. A maximum of 3 BACKlight can be installed
consecutively from any power feed.
Note: Do not solder or unsolder any cables. Use only
terminals to connect the LED modules since otherwise
the protective coating will be damaged or destroyed.
Channel Letter
Page 4 of 8
Application document for Backlight LM03A
Version: 02.08.2005
Design
Initial assembly
Version a
Mechanical assembly
Mechanical assembly
Depending on the bar thickness of the letter it should be
fitted with 1 or 2 rows of BACKlight LED modules.
Bar thickness up to 110 mm: 1 row
Bar thickness over 90 mm: 2 rows
Note: To achieve homogeneous, powerful illumination
the chains are extended to 1/2 to 2/3 length.
Step 1
Attach the metal holders to the base of the letter by spot
welding.
Step 2
Secure the BACKlight modules, or at least every other
module, hand tight using an M4 screw.
Note: During the assembly work symmetrical spaces
from the LED module to the letter walls will produce the
best economy rate and homogeneous illumination.
4.
5.
Fitting the LED modules on to the metallic base of the bottom section of the letter.
Channel Letter
Page 5 of 8
Application document for Backlight LM03A
Version: 02.08.2005
Version b
Mechanical assembly
To fit the BACKlight with screws
Step 1
Predrill the holes in the rigid PVC foam base. Or insert the
screws without drilling using a power screwdriver.
Step 2
Secure the BACKlight modules, or at least every other
module, hand tight using an M4 screw.
The use of spacer sleeves is the best method of
assembly since they keep the LED module at a fixed
distance from the rear panel. Rainwater that ingresses as
a result of the letter not being 100% sealed and would
otherwise run down the rear panel, would then not come
into direct contact with the LED modules.
Note: All BACKlight modules are coated with a highly
effect protective coating at the factory. This protects the
LED module against moisture and condensation. In no
circumstances may the module be operated in water or
under running water.
Fitting the LED modules to the double (rigid PVC foam) base.
Channel Letter
Page 6 of 8
Application document for Backlight LM03A
Version: 02.08.2005
Initial installation
Electrical connection of the modules
The electrical connection of the open cable ends is made
using terminals or wire nuts.
All the modules are connected in parallel.
A maximum of 3 BACKlight modules may be connected
consecutively (parallel).
Step 3
Connect the positive pole (red cable) of the first chain to
the positive pole of the next chain. Then connect the
negative poles (black cables) to each other.
Note: Do not connect BACKlight modules in series!
If the letter contains more than 3 modules, a new power supply may be inserted or star points may
be formed.
6.
OT50/220-240/10
OT50/120-277/10 E
50 Watt / 10 VDC
Module 1 right Module 2 right Module 3 right Module 3 left Module 2 left Module 1 left
Rated power for 3 modules approx. 12 W Rated power for 3 modules approx. 12 W
Module 3 left Module 2 left Module 1 left Module 1 right Module 2 right Module 3 right
Rated power for 12 modules approx.
48 W
Channel Letter
Page 7 of 8
Application document for Backlight LM03A
Version: 02.08.2005
Initial installation on the double base
Final installation
Channel letter casing
Screw in the spacers
Step 4
The full letter is electrically wired as shown in Step 3. All
BACKlight module chains are compiled into star points in
units of three (maximum 3 BACKlights to be connected in
parallel). The connection to the supply cables from the
power supply or power supplies is also made at the star
points.
Step 5
Drill holes for threaded rods in the empty bottom section
of the letter. Then insert the rods and secure them at the
front and rear with nuts.
Step 6
Secure nuts with washers at the upper end of the
threaded rods.
The threaded rods with the washers are used as spacers
and a support surface for the rigid PVC foam base fitted
with the LED modules.
Note: Secure the threaded rods with no play using the
nuts.
7.
Channel Letter
Page 8 of 8
Application document for Backlight LM03A
Version: 02.08.2005
Installation and connection of control unit
Connecting the modules to the control unit
Step 7
Secure the power supply in the letter. The fastening holes
on the OT50/230-240/10 and OT50/120-277/10 E are
under the caps.
Step 8
Connect the power supply both on the secondary side to
the LED modules and on the primary side to the mains
cable.
Note: The electrical installation and the appropriate
fusing are to be completed as set out in the current
installation regulations.
Step 9
The distance between the rigid PVC base and the acrylic
glass must be selected such that on the one hand the
power supply has enough space between the double
base and on the other that the distance between the LED
modules and the acrylic glass is as small as possible.
Note: The minimum distance between the LED
modules and the acrylic glass is approx. 30 - 40 mm.
If the actual distance is below the minimum value of
30 mm, individual LED may make light points visible,
which means that the backlighting is not homogeneous.
The perfect distance between the LED modules and the
acrylic glass is approx. 40 - 80 mm.