Otis Singleton
Neon signs are known for their bright glow, but they can be dangerous if not handled properly. Before attempting any repairs, it is crucial to ensure that the power is turned off at the circuit breaker panel and all power is disconnected from the sign's electrical supply box to avoid the risk of electric shock. Older neon signs, in particular, should be handled with caution and taken directly to a professional for repair. While some issues, such as loose wires or broken LED strips, can be fixed through simple repair techniques, more complex problems like broken glass or transformer malfunctions may require professional assistance. Regular maintenance, including cleaning and leaving the sign on 24/7 when not in use, can help prevent issues and minimise the need for repairs.
| Characteristics | Values |
|---|---|
| Safety precautions | Always turn off and unplug the neon sign before handling or repairing it to avoid electric shock |
| Common issues | Flickering, dimming, broken tubes, faulty wiring, transformer malfunctions, loose connections |
| Troubleshooting | Check power supply, inspect LED strips/tubes, test transformer voltage, trace wires back to source |
| Repair methods | Replace damaged parts, refill gas, perform welding and sealing, reconnect wires, solder on new LED segments |
| Maintenance | Regular cleaning, leaving the sign on 24/7, checking for gas leaks, adjusting power supply voltage |
| Professional repair | Recommended for older signs, complex issues, broken glass, mounting issues, converter/transformer replacement |
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What You'll Learn
Take safety precautions
Safety should be a top priority when repairing a neon sign, as you will be dealing with high-voltage electronics and fragile glass tubing. Before attempting any repairs, make sure to take the proper safety precautions.
Firstly, always turn off and unplug your neon sign before handling it. Failing to do so could result in a severe electric shock, as neon signs run on very high voltages of around 9,000 to 20,000 volts. Therefore, handling a neon sign while it's plugged in can be extremely dangerous and even fatal. Additionally, wear protective gear, including gloves and eyewear, to shield yourself from broken glass, which can be razor-sharp. If you need to transport the sign, wrap it securely with foam padding or a blanket to prevent further damage.
It is also important to be cautious of the materials inside the neon sign. Although the amounts of lead and mercury are typically small and non-toxic, you should still be careful if you suspect a break or leak. Wear a mask in addition to gloves to protect yourself from any potentially harmful substances.
If you are uncomfortable with any part of the repair process, it is best to consult a professional. Older neon signs, in particular, should be handled by a specialist, as they can be extremely dangerous if repaired incorrectly. Professionals will be able to diagnose the problem and provide an accurate quote for repairs. They have the technical expertise and knowledge to handle a wide range of issues, from electrical problems to damaged tubes and wiring.
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Identify the problem
Before attempting to repair a neon sign, it is important to identify the problem. Firstly, if your sign is an older model, it is recommended that you do not try to repair it yourself and instead take it to a professional. Older signs can be extremely dangerous if handled incorrectly as they require a very high voltage to function, typically between 9,000 and 20,000 volts. Always ensure that your sign is unplugged and powered off before handling to avoid the risk of electric shock.
If your sign is newer and intact, there are several common issues that you can identify and potentially fix yourself. The most common problems with neon signs include flickering, dimming, or complete failure to light up. These issues are often caused by a broken connection, faulty transformer, damaged tubes, or broken LED strips.
If your sign is flickering, the cause is most likely a loose connection somewhere in the sign's wiring. You should check all cable connections to ensure your sign is wired correctly. If this is not the cause, the problem may lie with the transformer or power supply. Use a multimeter to check if the transformer is supplying the correct voltage. If the transformer is faulty, it will need to be replaced, which can be done at home or by a professional.
If your sign is dim or not lighting up at all, the issue could be a broken LED strip. Inspect the LED strips carefully and, if necessary, use a soldering iron to reconnect any loose wires or solder on new LED segments. If your sign is unable to turn on at all, the problem is most likely faulty wiring or a broken converter.
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Check for power issues
Before attempting any repairs on a neon sign, it is crucial to prioritise safety. Neon signs, especially older ones, can be extremely dangerous if mishandled. Always ensure the sign is unplugged and powered off before touching it. The average neon sign operates with 9,000 to 20,000 volts of electricity, and mishandling a live sign can result in a fatal electric shock.
Once the sign is safely powered down, you can proceed to check for power issues. If your neon sign is unable to turn on at all, the problem is likely related to the power source, power supply unit, or faulty wiring. Begin by checking all cable connections to ensure the sign is wired correctly. If the wiring seems intact, the transformer may be malfunctioning or the power supply could be faulty. Use a multimeter to test if the transformer is supplying the correct voltage. If the transformer is faulty, you may need to replace it.
If your sign can turn on but shuts off after a few minutes, the issue is likely a faulty connection, a faulty power supply, or a worn-out transformer. Check for loose connections and ensure the power source supplying electricity is functioning correctly. If the problem persists, you may need to replace the transformer or converter.
If your sign is experiencing flickering or dimming, this could be due to a loose connection, a faulty power supply, or worn-out LED strips. Inspect the LED strips for any damage and test the power supply voltage using a test pen or multimeter. If the power supply is insufficient, adjust it to the appropriate level.
While some minor issues can be addressed through DIY solutions, it is recommended to consult a professional for more complex problems or larger signs.
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Inspect for damaged parts
Before attempting to repair a neon sign, it is important to inspect it for any damaged parts. This is because the repair process can vary depending on the type and extent of the damage. Here is a step-by-step guide to inspecting a neon sign for damage:
Firstly, identify any visible cracks or breakages in the glass tubes. Even small cracks can cause the sign to stop working, and if large gaps or significant damage is present, the tube may need to be replaced. When handling broken neon glass, it is crucial to wear protective gloves and eye gear to prevent injuries and exposure to the gas mixture inside the tubes.
Secondly, check for any loose or damaged wires, as these are a common cause of flickering and sudden shut-offs. Inspect the connections and wiring, tightening or replacing any loose or damaged parts as necessary. Cut and strip damaged sections of wire using wire cutters, and remember to disconnect the sign from the power source before handling.
Thirdly, examine the transformer for any damage or malfunctions. The transformer converts electricity into the high voltage needed for the neon gas to glow, so a faulty transformer can cause the sign to flicker, shut off, or stop working altogether. If you suspect the transformer is the issue, it is recommended to consult a professional, as transformers carry a high voltage and can be dangerous.
Finally, inspect the sign for any other physical damage, such as broken electrodes or compromised mounting. These issues can often be repaired or replaced by a skilled technician. It is also important to regularly clean your neon sign to prevent dirt and debris from accumulating and causing issues. Remember that older neon signs, in particular, can be extremely dangerous if handled incorrectly, so always prioritise safety and consider seeking professional assistance if you are unsure.
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Call a professional
If you have an older neon sign, it is highly recommended that you do not attempt to repair it yourself and instead take it to a professional. Older neon signs can be extremely dangerous if handled incorrectly as they expose gas encased in glass tubing to high voltages to shine. This means that failing to turn off and unplug your sign before handling could result in a severe electric shock.
Professionals will be able to diagnose the problem and determine how expensive it will be to fix. They will also be able to advise on whether your sign is simply getting old, as neon signs only have a lifespan of around 10-12 years on average.
Even if your sign is newer, it is still recommended that you seek a professional opinion. DIY fixes for broken neon signs are generally only applicable for issues like a broken transformer or wires that have shorted, and if done incorrectly, can be dangerous.
If you are unsure about carrying out a diagnosis yourself, it is advisable to seek professional assistance. Experienced and qualified neon sign repair technicians have the technical expertise and specialised knowledge required to identify and rectify the diverse array of malfunctions that can plague a neon sign. They will be able to identify whether the problem is with the neon tubes, such as cracks or leaks, or with the transformer or wiring.
If the issue is with the mounting of your neon sign, you should consult a professional for secure reattachment. Improper mounting can cause damage, which can increase repair costs.
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Frequently asked questions
Before attempting any repairs, ensure the sign is unplugged and the power is off at the circuit breaker to avoid electrical accidents. Older neon signs, in particular, can be extremely dangerous if handled incorrectly.
Unfortunately, if your transformer is broken, you will need to replace it. You can buy a replacement at a hardware store.
Neon sign flickering is often caused by a loose connection somewhere in the sign's wiring. Check all cable connections to ensure your sign is wired correctly. If this is not the cause, try to determine whether your transformer is functional.
