FACTORY STRETCH INSTALLATION INSTRUCTIONS

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Meghan Gallagher
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1 !! Important!! Make sure all power is disconnected prior to installation. Wiring to be done according to Local and National Electric Codes by a qualified electrician. Make sure the building and/or structure is of sufficient size & strength to support the Illuminated Fascia System in local conditions (i.e. weight, wind, etc.). Overview of Steps for Proper Installation Check site layout plans against actual site dimensions. (If discrepancies exist, call LSI Industries at (800) ext. 3300) Install cabinets. At least (6) Z-clips per cabinet are required. Adjust lighting and make wiring connections. Install access panels/ closed end panels/ eggcrate panels/downlight lens panels. INFORMATION & SPECIFICATIONS Drills w/ 5/16 hex & Philips driver Drill bits Screwdrivers Hammer Several C-clamp vice grips w/flat jaws Quick grips Spring clamps Sawsall or hack saw Tools Required Tin snips Socket set Caulking gun Utility knife Tape measure 4 Level Chaulk line Ladders, scaffolding, scissors lift, etc. No. of People Required It is recommended that at least three people be available for installing fascia up to 30 feet long - and one additional person for every additional 12 feet. Specifications Fascia system is 11 deep. 800mA rapid start lamps. Ballasts rated for 20 C. UL Listed E Patent no. 4,512,098 Cold Weather Notice: When installing factory stretched faces in cold weather, it may be necessary to use a heat gun on the folds before opening to prevent possible damage to the face. For information on cold weather installations, call LSI Industries at Patents Pending 2

If there are any concerns with actual dimensions versus plan dimensions call LSI Industries at (800) 436-7800 ext. 3300. Install Cabinets Important!

2 Check site layout plans against actual dimensions 1. An installation layout plan and fascia art work is furnished with the job. Confirm the dimensions on the layout by measuring the building and/or structure where the cabinets will be mounted. If there are any concerns with actual dimensions versus plan dimensions call LSI Industries at (800) ext Install Cabinets Important!! Use appropriately sized fasteners (supplied by contractor) and Z-clips (supplied by LSI Industries) for mounting cabinets to structure. Never mount cabinets by pre-paint white back skins. Back skins are not designed to carry the cabinet load. At least (6) Z-clips per cabinet are required. 2. All cabinets are numbered corresponding to their location in the system. We recommend arranging cabinets in sequential order along the ground in preparation for installation and to facilitate proper wiring. Note: Typical cabinets measure 90 long. Corner cabinets measure 84 long. 3. Review site prints to obtain cabinet mounting heights and make appropriate markings on the building and/or structure to make sure cabinet installation is level, square, etc. 4. Determine the best starting point for mounting cabinets and begin mounting cabinets. At least (6) Z-clips per cabinet are required for proper mounting (3 along the top and 3 along the bottom). 5. Cabinets attach to one another by screwing adjoining gussets together using #10 x 3/4 TEK screws. TEK screws found in the hardware pack. Make sure there is no gap between cabinets where the back extrusions with gasketing come together. 6. Biscuits are provided for T-frame alignment at cabinet joints. Slide biscuits in top and bottom T-frame groove and screw in place with #10 x 3/4 TEK screws provided. Make sure T-frame is pulled together tightly with no gap. Z-clip # 12 x 1 TEK screw Fastener (by others) #10 x 3/4 TEK screws 3

3 7. For straight runs of cabinets, it is often necessary that one cabinet be a non-standard length (also know as an odd size cabinet ). Insight Graphics provides one odd size cabinet per straight side designed to be field cut down to a desired length. The components of the cabinet can be disassembled, cut down to size and reassembled. To cut down the odd size cabinet, begin by loosening the nuts and bolts on the horizontal cabinet extrusion and T-frame. This can be done on either end of the cabinet. Remove the vertical tube and the gussets as a unit. (NOTE: Do not loosen the nuts and bolts that attach the gussets to the vertical tube.) Cut down the horizontal tubes and back skin to the desired length and reassemble. Note: odd size cabinet is usually located next to a corner cabinet or an end cabinet 8. Due to the packaging for shipping, some lamp track housings may not be in the proper location. These lamp tracks are usually for the odd size filler cabinets and are located in the cabinet to the left of the odd size cabinet. Relocate the lamp track housing by lining up the arrows on the stickers. When complete, all lamp housings should overlap, approximately six (6) inches. Do not disconnect any of the electrical wiring. It is pre-wired and tested in the factory. overlap lamps 6" 9. Run electrical wires, located inside flexible conduit, from ballast to ballast. Make sure conduit is neatly tucked behind lamp tracks to avoid shadow. 10. Use conduit connectors supplied to screw into open end of conduit. Insert conduit connector into hole in ballast box end and securely tighten lock nut. Connect same color electrical wires from ballast to ballast. Prepare for remaining cabinets. 11. If electrical primary circuitry has been supplied by electrician at time of installation, proceed by connecting our junction boxes to the circuitry. If the circuitry hasn t been supplied, just pigtail out the back of the cabinet s junction box for easier hookup by the electrician. 12. Insert lamps into lamp track housings. Test each circuit to ensure all lamps and ballasts are working. NOTE: CLEAN ALL DIRT AND SHAV- INGS OUT OF THE INTERIOR OF CABI- NETS. 13. Spread cardboard from cabinet packing out along the ground in front of cabinets to receive face. This will protect the fascia when it is being unpacked and assembled for installation. 4

4 14. The fascia cartons have a written number corresponding to the cabinet that will receive the face. Find the face you desire and turn it on it s edge. Carefully unfold it accordion style onto the cardboard, making sure not to scuff or damage it. Carefully lay face down onto the cardboard. 17. Each shipping brace is a one piece tubular bar bent and punched at each end. Remove every other brace and loosen the screws on the remaining braces. These remaining braces provide important reinforcement to the fascia frame while it is being hoisted into mounting position. 15. There are two types of fascia frames: 1 x 1 tubing and 1 x 1 angle frame, which assemble differently. Be sure to use the proper set of instructions. NOTE: REMOVE ANY DIRT OR SHAV- INGS FROM INSIDE OF FACE BEFORE INSTALLING. 1" x 1" TUBING FRAME 16. At the top and bottom of every frame section there is a 4 gap. At this gap there is a double slide lock mechanism. To fill this gap in the frame, you have to insert a 4 spacer, which you find in the hardware box. 9/64" 1 x 1 ANGLE FRAME 18. Locate the joint brackets which are numbered as follows: 1-T for top and 1-B for bottom corresponding to the same (1T, 1B) marked on each joint of the face. Match all brackets with all joints. 19. To help install the joint brackets, a temporary joint bracket separator tool is supplied. Insert the tool between the two shipping braces at each joint. Using a 3/4 wrench, tighten the nut until the material stretched open enough to insert bracket easily. DO NOT OVER STRETCH. Fasten with the 5/8 self-tapping Phillips head screws supplied. Remove separator tool. 7/32" After the spacer is in place remove the screw at each slide lock, then engage the slide lock into the spacer. To secure the slide lock and spacer use the screw that was removed. (NOTE: There are two sets of holes in the spacer) before engaging the slide lock make sure that the two 7/32 holes are facing the tube on the top or bottom and the 9/64 holes are facing away from the fascia material. Using pop rivets and the 9/16 holes, attach the fascia material to the 4 spacer. 5

20. Install the frame bows which are numbered to match the face. The amount of frame bows varies depending on the length of the face. A frame bow is placed every 6 and is pre-drilled.

5 20. Install the frame bows which are numbered to match the face. The amount of frame bows varies depending on the length of the face. A frame bow is placed every 6 and is pre-drilled. Align with holes and fasten with the self-tapping screws supplied. 23. Starting at one end, at the top, fasten the face into the cabinet using the #12-14x1 tek screws. Insert the screws through the pre-drilled holes in the T-frame and into the face frame. After all top screws are in, repeat this process on the bottom. Angle frame 24. Once all faces are installed, bolt the mitered corner faces together. Do this using a pair of vice grips to pull both faces together. Fasten with 1/4-20 x 3/4 bolts, nuts, and star washers. When all bolts are tight, remove vice grips. Frame bow 21. Once all of the frame bows are installed, remove all of the shipping braces. 25. Remove all shipping braces that remain. All shipping braces must be removed to prevent shadowing. NOTE: REMOVE ALL DIRT AND SHAV- INGS FROM INSIDE OF FACES BEFORE INSTALLING. 26. If this system has downlight lenses, install the corner lens first. This is done by hooking the front side onto the T-frame and pushing it up into place. The back is held into place using #10 x 1-1/2 pan head screw (3) per panel. 22. Attach lifting ropes to shipping braces or frame bows approximately every 12 feetrope must pass through top of cabinets. Be very careful when lifting the face making certain to keep it level at all times. #10 x 1 1/2 Pan Head Screw (3) per panel 6

Installing access panels/ closed end panels/ eggcrate panels Installing Top Access Panels 1. Top access panels are designed one per cabinet.

The bend on the back of the top access panel is designed to fit into the space between the back of the cabinet and the building.

4 TEK gasketed screws; clearance holes are provided for screw locations. 3.

6 Installing access panels/ closed end panels/ eggcrate panels Installing Top Access Panels 1. Top access panels are designed one per cabinet. Silicone caulking must be applied at each seam to prevent water entry. Remove access panels from carton and install. 2. The bend on the back of the top access panel is designed to fit into the space between the back of the cabinet and the building. Install top access panels from left to right using #10 x 3/4 TEK gasketed screws; clearance holes are provided for screw locations. 3. Caulk all seams on top access panels and back of cabinets Silicone caulk #10 x 3/4 gasketed TEK screw Top access panel Installing Bottom Access Panels 1. Bottom access panels are designed one per cabinet. Note: Caulking is not required for bottom access panels. 2. The hem on the front of the bottom access panels is designed to hook onto the Z-extrusion and the bend on the back of the bottom access panel is designed to fit into the space between the back of the cabinet and the building. Install bottom access panels from left to right using #8 x 3/4 white wafer head screws; clearance holes are provided for screw locations. Top corner access panel Silicone caulk Bottom corner access panel #8 x 3/4 white wafer head screw 7

Installing access panels/ closed end panels/ eggcrate panels...continued Installing End Panels The hem on the front of the end cover is designed to hook on the Z-extrusion.

The bend on the short side of the panel is designed to fit over the top gusset and under the top access panel. Along with the end panel you will find a trim piece (1 x 3 x 11 ).

7 Installing access panels/ closed end panels/ eggcrate panels...continued Installing End Panels The hem on the front of the end cover is designed to hook on the Z-extrusion. The bend opposite the hem is designed to fit into the space between the back of the cabinet and the building. The bend on the short side of the panel is designed to fit over the top gusset and under the top access panel. Along with the end panel you will find a trim piece (1 x 3 x 11 ). This trim is designed to fit under both the end cover and the bottom access panel. Use #8 x ¾ wafer head screws (found in a hardware box) to fasten the end cover and trim piece. Installing Eggcrate and Downlight Lens Panels These panels are designed to hook onto the T- frame extrusion along the front and screwed to the cabinet along the back edge using the holes provided. Use #10 x 1-1/2 pan head screws to attach eggcrate. #10 x 1 1/2 Pan Head Screw (3) per panel Trim (1 x 3 x 11 ) 8

8 ATTENTION When removing premask from the face (if applicable), gently pull up one end and tear off at 180 angle, folding the premask back over itself. Do not remove by pulling the premask straight from the face, this may result in removal of film. FACE Premask Protective Covering 9

9 Installation Bulletin 1.1 March 30, 1993 The following instructions are specifically for panaflex flexible sign faces, but are good guidelines for any flexible sign face. The following quote is from 3M Instruction Bulletin 6.3 dated September, 1991: When the temperature is below 45 F, avoid installations (i.e., attaching finished sign faces to cabinets, framing, etc.) where folding, crimping, creasing, or forming the materials to sharpen corners is necessary. At low temperatures, the material becomes less flexible and cracking may occur. Overnight storage in a heated environment is recommended where possible and the use of a heat gun at the folds, just prior to unfolding. LSI Industires will not accept responsibility for damage to fascia material due to cold weather installation. Please call Field Service at with any questions. 10

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