Installation Instructions 3M Light Mat Series 3635-1000 Installation Bulletin 3635-1000 Release D, Effective July 2010 (Replaces C, Apr 2010) See Bulletin Change Summary at end of Bulletin Product Description Product Numbers Product Specifications and Warranty Information 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. 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 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: 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
! 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! 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.! CAUTION When handling any chemical products, read the manufacturers' container labels and the Material Safety Data Sheets (MSDS) for important health, safety and environmental information. 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 Max Amperage Max Watts per Channel 1.8-20V 5A 100W 1.8-24V 4.16A 100W 1.8-42V 2.0A 100W Light Mat Installation Kit 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 Helpful but not required or supplied 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) Installation Bulletin 3635-1000 - 2
Remove Existing Electrical Components For retrofit kits only For retrofit applications the light mat and power supply are each marked with the UL Classification Mark. 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 jurisdiction 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
Cutting the Light Mat! 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. É ÉÉ ÉÉ É ÉÉ 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. Power Supplies If Cutting Is Needed Perimeter Caulking 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. If the copper circuitry in the Light Mat is exposed due to cutting or damage, the exposed circuitry 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. 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 exceeding 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
All installations must comply with UL conditions of use as noted in the power supply manufacturers 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 Section of Sign UL Listing Mark. The source ground and power supply case should be electrically tied to the electrical enclosure. - If minimum size enclosure is specified by the power supply manufacturer It is recommended 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 separate 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. Installation - 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. 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 Scotch 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
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. FIGURE 3 Use Two Hands to Remove Liner Note: 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. Wiring Attach the wires to the LED power supply, matching the labels on mating parts. Refer to the Wiring Diagram. - 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). Wiring Diagram Line Neutral Ground Line: Black Neutral: White Ground: Green, if present +V 3M Light Mat Series Class 2 3635-1000 Power Supply DC Gnd 120 VAC 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
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 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 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 Warranty and Limited Remedy FCC Rules, Part 15 Compliance 3M Related Literature 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. 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. 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 indicated 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 -3M Blockout Films 3635-20B, 3635-22B -3M Diffuser Films 3635-30, 3635-70 -3M Day/Night Films 3635-91 PB 3635 3M Graphics Market Center Warranty Brochure 3M is a trademark of 3M Company. go to www.3mgraphics.com, Warranties Installation Bulletin 3635-1000 - 7
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 3M 2010. All rights reserved. Installation Bulletin 3635-1000 - 8