Retrofitting an Illuminated Sign with LED Modules: GL 8018 and GL 6018

1. Decide whether the existing sign is worth retaining

Inspect the cabinet for corrosion, loose fixings, damaged seals and water paths. Check the face for cracking, yellowing, staining or graphics that no longer transmit light evenly. A new light source cannot restore a damaged diffuser or unstable structure. Record access constraints and whether opening the sign requires lifting equipment or disruption to the business.

Measure actual face distance at several points and note old lamp supports, braces and unused wiring. Separate reusable fabrication from electrical equipment that needs removal or replacement. Ask a competent installer to assess the existing circuit, isolation, earthing where applicable and protective arrangements. Do not assume old wiring is suitable because the new module circuit is only 12V.

2. Record the old appearance and input power

Photograph the sign before work from the normal viewing position, including the weakest area and any colour differences. Record operating hours and controls. If energy savings are part of the proposal, measure the complete old sign's mains input with suitable equipment operated by a competent person. Lamp nameplate watts alone may omit control-gear losses or failed lamps.

Agree what the replacement must achieve: similar face brightness, a changed colour appearance, better uniformity or improved repair access. A comparison is meaningful only if the new sign delivers an agreed useful result. A deliberately dimmer replacement can use less power without meeting the customer's original brief.

3. Trial GL 8018 and GL 6018 in the existing cabinet

GL 8018 PRIME is listed at 1.5W per module in an 80 × 18mm body; GL 6018 PRIME is listed at 1W in a 60 × 18mm body. Both require 12V DC and have a published 160° beam. Use those figures to compare physical fit and calculate load after the optical trial, rather than to predict a universal replacement ratio for fluorescent lamps.

In an open cabinet, the longer GL 8018 may offer practical placement across broader areas. The shorter GL 6018 may help around retained braces or irregular sections. Test with the existing face and intended backing finish. Check the hardest edge and any formerly shadowed area. If the face itself is unsuitable, include replacement material in the proposal and test it separately.

4. Build a new electrical layout

Do not connect 12V modules to a fluorescent ballast, neon transformer or an output with the wrong voltage or control mode. The retrofit needs a compatible constant-voltage supply and a distribution design for the final load. Have obsolete equipment disconnected and removed appropriately, with waste handled through a suitable route for the materials involved.

For example, 60 GL 8018 modules plus 20 GL 6018 modules total 90W + 20W = 110W nominal, approximately 9.17A at 12V. An optional 80% planning target starts at 137.5W of rated capacity. The actual supply must meet its continuous and thermal limits in the cabinet. These example counts do not establish optical suitability.

Map parallel branches and calculate current in each feed, checking terminals, cable ratings, voltage drop and product chain limits. Existing lamp spacing should not become LED spacing by default. Keep supply outputs separate unless the manufacturer expressly supports another arrangement, and retain access to the driver and junctions.

5. Calculate savings from measured mains input

After commissioning at the approved brightness, measure the new complete sign's mains input. Module watts are DC load figures, while the supply adds losses; therefore compare old and new measurements at the same boundary. Use realistic hours rather than a default assumption of continuous operation.

An illustrative old measured input of 240W and new measured input of 125W gives a 115W reduction. At 10 hours per day for 365 days, that is 0.115kW × 3,650 hours = 419.75kWh per year. Multiply by the customer's actual unit tariff to estimate annual energy cost reduction. These are hypothetical figures, not a saving claimed for either module.

Assess payback using the complete installed cost, including face repairs, electrical work, access equipment and downtime. Keep any expected maintenance saving separate from measured energy saving; actual future repair costs are uncertain. A timer or control change also affects operating hours and should be identified in the comparison.

6. Correct inherited water and heat problems

Deal with water paths before fitting new components. Select module joints, cable entries and the power supply's location for real rain, cleaning and condensation exposure. The PRIME module IP65 rating applies to its enclosure under defined tests, not the entire retrofitted sign. Follow fixing and sealing instructions for the chosen products.

A new driver still generates heat. Check its clearance and operating conditions in the existing cabinet, including hot conditions caused by sun exposure. Avoid covering components with insulation or placing them where a face repair will make future service impossible. Keep the mounting and cable arrangement documented.

7. Commission and document the completed retrofit

Test the complete sign at full intended output, checking branch voltage at distant modules, stable operation, uniformity and controls. Inspect the appearance after the face has been refitted because final brackets and cable positions can create new shadows. Resolve faults before accepting the sign as complete.

Give the customer the module variant, supply model, wiring record, photographs and any measured energy comparison. Keep a copy of installation and warranty documentation. A clear record supports future colour matching and distinguishes a supply fault from a branch fault without repeating the original survey.