Quick answer: Most dark or flickering lightboxes and channel letters can be repaired or converted to LED instead of replaced. A retrofit swaps old fluorescent tubes and ballasts for an LED kit; the National Electrical Code requires retrofit kits to be Listed, and UL notes many jurisdictions require a permit for the work. If the cabinet or letters are sound, a new face plus an LED retrofit usually costs far less than a new sign.
Common Sign Problems
- Lightbox dark or half lit: fluorescent lamps and ballasts wear out. When one ballast fails, a whole section goes dark. Flickering at the ends of a tube is often the first warning.
- Channel letters out: one or two dark letters usually point to a failed LED module string, a power supply, or a loose or corroded connection. Water getting into a letter can short it.
- Sign on at the wrong times, or not at all: a failed timer, photocell or switch is a quick, inexpensive fix.
- Faded, cracked or yellowed faces: sun and age make polycarbonate and acrylic faces brittle and dull. Printed or vinyl graphics fade first on south- and west-facing signs.
- Storm damage: wind can crack faces, bend returns or loosen mounting. Have it checked before it gets worse.
- Rust and water stains: on older steel cabinets, rust around seams and drain holes is a sign of water getting in.
What an LED Retrofit Involves
An LED retrofit takes out the old fluorescent tubes, sockets and ballasts and installs LED modules or strips with a new power supply inside the existing cabinet or letters. The cabinet, frame and often the face stay. The U.S. Department of Energy notes LEDs are highly efficient for colored-light uses such as exit signs, and they don't have the fragile glass tubes of fluorescent lamps.
Two code points matter. First, according to UL, the National Electrical Code requires sign retrofit kits to be Listed. A kit pieced together from off-the-shelf parts is treated as field-modified equipment, which can complicate inspection. UL Certified kits carry the UL Certified Mark on the installation instructions. Second, NEC Article 600 requires a retrofitted sign to be marked to show that it was retrofitted, including the kit provider and the installer.
Repair, Retrofit or Replace?
- Repair when one part has failed (a ballast, a power supply, a timer or a single letter) and the rest of the sign is in good shape.
- Retrofit to LED when the fluorescent system keeps failing, you're tired of replacing tubes, or you want lower energy use and fewer service calls, and the cabinet is still sound.
- New face when the lighting is fine but the face is faded, cracked or shows an old name. Paired with a retrofit, a new face can make an old sign look new. See our storefront sign cost guide for how faces compare to full replacement.
- Replace when the cabinet is rusted through, the structure is loose, or you're rebranding and want a different style, such as channel letters instead of a box.
Permits and Who Can Do the Work
UL notes that many jurisdictions require a permit and approval from the local code authority for a sign retrofit, and that qualification requirements for installers vary. Some areas require a licensed electrician. In Rockland County, signs are handled by the village building department (Spring Valley, Suffern, Airmont and the other villages) or by the town for hamlets like Monsey (Ramapo), Nanuet and New City (Clarkstown) and Pearl River (Orangetown). If you're changing the sign's face or size, not just the lighting, it may need sign review as well. Our Rockland storefront sign guide covers the permit process.
If you lease your space, check your lease. Many landlords want to approve any work on signage, and some plazas have rules for face colors and lighting.
Keeping a Sign Working
- Check your sign after dark every week or two. It's easy to miss a dark section when you only see the sign during business hours.
- Look for water stains, rust and loose fasteners after big storms.
- Keep the timer or photocell set to your hours and adjust for daylight saving time.
- Wipe faces with mild soap and water and a soft cloth. Harsh cleaners can cloud acrylic and polycarbonate.
What to Send for a Repair Quote
Send a daytime photo and a nighttime photo of the sign, the address, roughly how high it's mounted, and what's wrong (dark, flickering, faded or damaged). If there's a label inside the cabinet or on the back of the sign, a photo of it helps. Call (845) 579-3685 or use the form below.
Common Questions
Can my old lightbox be converted to LED?
Usually, if the cabinet is structurally sound and dry inside. The fluorescent lamps and ballasts come out and a Listed LED retrofit kit goes in. The sign is then marked to show it was retrofitted.
Do I need a permit to retrofit a sign to LED?
Often. UL notes many jurisdictions require a permit and approval from the local code authority for a sign retrofit. Your village or town building department can confirm.
Why is only part of my sign lit?
Common causes are a failed ballast or LED power supply feeding one section, a burned-out tube, a loose connection, or water in a channel letter. A tech checks power, then each section.
Is it worth repairing an old sign or should I replace it?
If the cabinet, frame and wiring are in good shape, repairing or retrofitting is often the better value. If the cabinet is rusted through or the faces are brittle and cracked everywhere, a new sign may make more sense.
Will an LED retrofit void my sign's warranty?
It can. UL notes retrofitting without the original manufacturer's permission could eliminate any remaining warranty coverage. On older signs that warranty has usually expired.
Sources
- UL Solutions Code Authorities, Sign Retrofit Kits: Installing LED Sign Retrofit Kits FAQs
- NFPA 70, National Electrical Code, Article 600 (Electric Signs and Outline Lighting)
- U.S. Department of Energy, LED Basics
Related
Custom signs · Channel letters · Sign costs · Sign size & permit guide · Window graphics · Service areas
Get a Quote
Call (845) 579-3685 or send details below.