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Wiring LED Modules for Lighting Signs -- Basic Rules

Wiring can be purchased from Middys @ http://www.middys.com.au/national-branch-directory

There are a few very basic rules to follow when wiring LED modules to transformers.
Follow these rules and you will ensure maximum life of both LED modules and Driver(s). Following these rules also ensures qualifying for your 5 year Warranty. (Click HERE for warranty details)

1. Never cross your wires.
It is imperative that you always connect Positive to Positive and Negative to Negative. If you fail to do this, the LED modules associated with a cross over, simply will not work!

Every LED module essentially has two wires in (+ & -) and two wires out (+ & -)

It does not matter if current flows through the module left to right or right to left.

The most popular modules supplied by LED sign supplies have common colors. Grey is Positive and White is negative.

2. Use 'Figure 8' cable that is bi-colored.
This cable is available in a number of different color configurations. The idea is that you use the Plain or single color for Positive and the Double-Color for the Negative.

NOTE -- remember "P"lain for "P"ositive.

The 'Figure 8' cable suggested is 14 strands of 0.2mm copper per color. A range of coloured cable is available in 100m or 500m reels.

3. Load Transformers to around 80% of Maximum rated load. (see Formula to get 80% of Transformer Load below)

Loading transformers under or over 80% of the transformer rated wattage, is likely to shorten the life of the transformer. Under or over working the transformer will limit the transformer life and nullify the warranty.

For example, if using a 100 watt Transformer, you need to load it to around 80 watt.

Transformers all have 110 - 240v input and 1 - 4 pairs of "+ & -" 12v output leads.

The number of output leads depends on the size (wattage) of the transformer.
15w, 18w, 30w & 40w transformers each have 1 x pair of 12v output leads.
60w & 100w transformers each have 2 x pair of 12v output leads.
150w transformers have 4 x pair of 12v output leads.

It is recommended that output 12v leads are evenly balanced to the number of LED modules there are connected to.

Example 1 - LED modules are usually supplied ready connected in chains of 20 modules. Each module is rated at 0.4 watts. Each chain then, is 20 x 0.4w = 8w.
4 x chains of 20 modules (80 x modules = 80 x 0.4w = 32w.) Based on a load of 32w, a 40w transformer is needed ( 80% of 40 = 32).
In this instance the 4 x pairs of leads from each of the 4 x chains, link direct to the 1 x pair of output 12v leads from the 40w transformer.

Example 2 -- 6 x chains of 20 LED modules = 120 modules. 120 modules x 0.4w/ module = 48w total. A 60w transformer is required here (80% of 60w = 48w). There are two output leads on a 60w transformer. To balance the load, you need to connect 3 x chains of 20 x modules to both output pair of leads.

Formula to get 80% of Transformer Load

Total LED Watts ÷ .8 (point 8)
eg 10 chains with 20 LED Modules per chain = 200 Modules.
200 x the watts per specific module (Module DVWM4s12v = .4 watts)
So 200 x .4 = 80 watts
80% of 80 watts = (80 ÷ .8) = 100 watt transformer

OHM’s LAW

In it’s simple form……….

Watts = Volts x Amps

(Amps = Watts / Volts)

So if you have two of the numbers (e.g. volts, amps) then you can find out the other (e.g. watts).
For more informaiton on Ohm’s Law – go to http://en.wikipedia.org/wiki/Ohm%27s_law

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