The most common LED solution for replacing fluorescent tubes is to house a strip of modules inside a glass or plastic tube with end caps made to fit into existing fluorescent light fixtures.

LED lighting has come a long way in the last 15 years, becoming a viable option for sign illumination along with neon, fluorescent and incandescent lighting in both commercial and residential applications. Sign companies can now consider LED versus other lighting options whenever an illuminated sign is sold, and the advancements in white light production have only made LED more attractive as an option. 

Fluorescent lighting has been promoted as a more efficient replacement for incandescent lighting, but recently the dangers of mercury contamination from fluorescent light disposal have risen in public awareness, and heavy fines and even jail time can be the consequences for violating disposal laws in some states. Unfortunately, it is not easy to properly dispose of or recycle fluorescent lamps, so tons of contaminated refuse gets dumped into landfills every year.

LED uses no mercury, has a high lumen per watt output, turns on immediately, operates without any buzzing, and has a considerable lifespan, all of which can make it a an environmentally friendly and budget friendly option for lighting of all kinds. The reduction in maintenance visits alone can be a huge cost savings, especially when you consider the cost to replace lamps in a high-rise cabinet sign. LED lighting has become a viable option for channel letters, backlit displays, outdoor sign cabinets, floodlights, and even retrofitting the overhead ceiling lights in your workspace. 

There are LED modules available for many applications in the sign industry, and some floodlight and recessed overhead lighting fixtures have been available, but the options for replacing the ubiquitous high-output tube-style fluorescent lamps in sign cabinets or T-bar ceiling fixtures have been sorely lacking.

Several LED manufacturers tried to fill the need by developing a replacement for traditional T8/T10/T12 fluorescent tubes with a strip of LED modules mounted inside a glass or plastic tube fit with end caps with pins made to fit into existing fluorescent light fixtures. Unfortunately, early designs have fallen short. In the effort to keep costs down, cheap materials are sometimes used and safety and durability are compromised. 

To comply with UL safety guidelines, the incoming voltage must be regulated to minimize the danger of receiving a shock during handling. Unlike fluorescents, which create resistance due to the current passing through the gasses in the tube, LED offers very little resistance, so unless the power is contained within one end of the fixture, the person changing the lamp could receive a 120-volt jolt. Also unlike fluorescents, if the tube housing the LED is broken, the lamp will still work, and because of the high cost of replacement, people are likely to leave a damaged lamp in use, increasing the risk of fire.

The solution? The required Class 2 power supply could be placed inside the tube fixture, but doing so raises the temperature significantly, so it must be well insulated from the LED modules or it can significantly shorten their life. Plus, a power supply would have to be in every tube, which increases cost. Another solution is to place the power supply separately from the lamp, requiring a bit more labor to install, but allowing the use of cheaper materials while complying with safety guidelines.

Putting the LEDs inside a tube reduces the light output, and the materials available for tube construction have their pros and cons as well. The most common choice is acrylic, which can be optically clear and durable, but at best is slow burning rather than self-extinguishing in the event of a fire. Glass is not flammable, but very breakable, unless thicker, more expensive glass is used. Polycarbonate is not flammable and unbreakable, but will cloud and yellow over time, reducing the light output even further. 

Recently, a different design has come to the market, offering kits to replace tube-style fluorescents in both backlit sign displays and overhead T-bar fixtures. Axiom NZ offers their AXLE7 Series LED module, which can be mounted to the back wall of a sign cabinet in strings, and is ideal for 5"-9" deep single-faced cabinets. It is a cost-effective alternative for both new and existing signs, and no more difficult to install than the standard fluorescent fixtures. The company has demonstrations of this product in use all over the world.

AoTuroaLED Kits retrofit any existing fluorescent fixture simply and safely.

While you are offering the LED alternative, let your clients know that there is also a solution that will save them money on their facility lighting. Since overhead lighting is typically further from the viewer than a backlit sign, and the light is intended to spread throughout the room rather than illuminate the back of graphics, the LED modules must be more numerous and more closely packed to achieve a satisfactory result. 

To make installation more user-friendly for the average maintenance staff, AoTuroaLED USA has packaged their retrofit kits with the LEDs mounted on strips that can be easily positioned in an existing metal T-bar fixture. The ballast is removed and replaced with the LED power supply using the same screws, and the retrofit is complete. To see a video of the kit being installed, visit http://www.youtube.com/watch?v=p64dnQSQ9zM. Their product uses the highest grade Nichia of Japan LED for ultra long lifetime, and it complies with UL safety standards.

According to AoTuroaLED, the AoTuroaLED Retro Kit uses up to 70 percent less power than comparable fluorescent fixtures, puts out 10 percent more light, boasts an extensive proven lifetime, and will pay for itself in energy savings and maintenance cost in a few years of operation. Kits can be purchased in any quantity, and replacement can be accomplished one fixture at a time or as a complete building overhaul, depending on the budget. There is also a federal tax credit available to businesses using this technology.

As an additional incentive, AoTuroa LED offers an affiliate program with a 10 percent commission on any sales made due to referral to their Web site. Their products will only be available through authorized distributors, sales agents, and their online Web store, so a signmaker could use their business connections to spread the word about sustainable lighting alternatives and build their bottom line at the same time.

There are environmental concerns about every lighting source. Whether you work with LEDs, neon or prefer fluorescents, as awareness of environmental issues grows and businesses continue to search for greener alternatives, it is up to each of us to stay informed and encourage others to act in a way that will ensure a cleaner, safer, brighter future for us all.