Links to specific brands of replacement tubes are to the left.
Click on pictures to enlarge.
First some warnings!
1. Neon sign transformers typically have an output of 4,000 - 12,000 volts.
Yes that's enough to kill you, at the very least it will knock you down.
Worse yet you might jump and break another tube on your sign, and you know how painful that is.
With a little care you will live through this.
Use common sense, if you have a weak heart, some medical condition or a
pace maker stay away.
2. Neon tubes are very fragile, you should treat them like you are diffusing a bomb!
One slip and boom, its broke. Ok, it won't kill you, but the thought of breaking another tube might.
3. Unless I say PLUG IT IN, leave it un-plugged.
Shortcuts to particular areas
Is it a tube or the transformer ?
Replacing neon tubes
Testing your neon tube(s)
Cleaning your neon sign
Painting your neon tubes
Re-assembling your neon sign
Parts & stuff
Is it a tube or a transformer?
Carefully (lightly) wiggle the tubes every couple of inches to check for breaks.
If broken, replace it.
None available? Check with a sign company to see about repair.
Usually the cheapest repair will be more than a replacement, and may not look as good.
No breaks?
You can do a basic check of the transformer by disconnecting the transformer lead wires from the tubes.
Find the spot where the transformer lead connects.
IF the insulation boot is loose slide it away from the glass tube, twisting helps (be careful don't twist the glass tube).
Assuming it isn't loose, you should heat it with a heat gun or blow dryer to
soften it, if still stuck cut it as described below.
Using a very sharp razor/knife, cut the insulation tube.
You MUST NOT push on the glass neon tube unless you support it with
your other hand (the hand you are about to cut if you slip).
Heating it before cutting helps too.
Now you can pull the insulation tube away from the glass tube.
You may need to lightly twist or cut it in several places.
You should see something like this, usually the wires are wound
well. Be careful, the neon tube electrode wires are tiny and you don't want to break them off, don't twist them too much!
After disconnecting both leads you can do a basic, non-scientific check of your neon transformer. (This will probably only work with the older heavy style transformers, the newer electronic ones may fail this test even if good.
Test the newer ones by trying another trans on your sign or hook your electronic trans to a known good tube.)
Try to arrange the leads so that the bare ends are about 1/2 inch apart.
Use wood blocks or wire ties to accomplish this. Also have a well insulated screwdriver or a stick handy. With the stick / screwdriver in one hand, plug in the transformer with the other.
Is the switch on? If not turn it on.
If you get no arcing try pushing one lead closer with the stick.
Still nothing? Try pulling the switch on. If you get an arc take the stick and widen the gap between the wires. Typically you can go about 1/2 to 3/4 of an inch before it quits arcing.
Not the best picture of an arc, but this is it.
If you get a tiny spark that barely will arc you have a bad transformer (sorry).
If you get nothing at all you may have a bad trans or better, a bad switch or cord.
UN PLUG it now!
If you suspect a bad switch, after un plugging, remove the small cover around the switch, unwire the 2 switch wires and wire the 2 wires that they connected to together.
Be sure to put a wire nut back on this connection.
Plug it in.
Now try the arc test again.
If you get a good arc, your switch was bad.
No arc, bad trans or bad cord.
You can check the cord for continuity with a test light. Be careful.
Transformers can be purchased from sign companies but can be pricey, friendly beer distributors can help get you one or point you in the right direction.
Ebay is a good source for both new and used transformers, search under neon transformer, sign transformer, neon power supply or tesla coil. You can also search out the brand names such as Franceformer. Just be sure you are buying a working transformer, watch for terms like "I don't know anything about this" or "as is".
As long as the input voltage (120v or 240v) and the output voltage (4,000v or 5,000v) and the output amperage (20ma or 30ma) is the same as your transformer, it will work. If it's a different size or style you may have to drill holes or whatever, but it will power the sign correctly. All this assumes the trans on your sign was the right one in the first place.
Click on pictures to enlarge.
First some warnings!
1. Neon sign transformers typically have an output of 4,000 - 12,000 volts.
Yes that's enough to kill you, at the very least it will knock you down.
Worse yet you might jump and break another tube on your sign, and you know how painful that is.
With a little care you will live through this.
Use common sense, if you have a weak heart, some medical condition or a
pace maker stay away.
2. Neon tubes are very fragile, you should treat them like you are diffusing a bomb!
One slip and boom, its broke. Ok, it won't kill you, but the thought of breaking another tube might.
3. Unless I say PLUG IT IN, leave it un-plugged.
Shortcuts to particular areas
Is it a tube or the transformer ?
Replacing neon tubes
Testing your neon tube(s)
Cleaning your neon sign
Painting your neon tubes
Re-assembling your neon sign
Parts & stuff
Is it a tube or a transformer?
Carefully (lightly) wiggle the tubes every couple of inches to check for breaks.
If broken, replace it.
None available? Check with a sign company to see about repair.
Usually the cheapest repair will be more than a replacement, and may not look as good.
No breaks?
You can do a basic check of the transformer by disconnecting the transformer lead wires from the tubes.
Find the spot where the transformer lead connects.IF the insulation boot is loose slide it away from the glass tube, twisting helps (be careful don't twist the glass tube).
Assuming it isn't loose, you should heat it with a heat gun or blow dryer to
soften it, if still stuck cut it as described below.
Using a very sharp razor/knife, cut the insulation tube. You MUST NOT push on the glass neon tube unless you support it with
your other hand (the hand you are about to cut if you slip).
Heating it before cutting helps too.
Now you can pull the insulation tube away from the glass tube.You may need to lightly twist or cut it in several places.
You should see something like this, usually the wires are woundwell. Be careful, the neon tube electrode wires are tiny and you don't want to break them off, don't twist them too much!
After disconnecting both leads you can do a basic, non-scientific check of your neon transformer. (This will probably only work with the older heavy style transformers, the newer electronic ones may fail this test even if good.
Test the newer ones by trying another trans on your sign or hook your electronic trans to a known good tube.)
Try to arrange the leads so that the bare ends are about 1/2 inch apart.
Use wood blocks or wire ties to accomplish this. Also have a well insulated screwdriver or a stick handy. With the stick / screwdriver in one hand, plug in the transformer with the other.
Is the switch on? If not turn it on.
If you get no arcing try pushing one lead closer with the stick.
Still nothing? Try pulling the switch on. If you get an arc take the stick and widen the gap between the wires. Typically you can go about 1/2 to 3/4 of an inch before it quits arcing.
Not the best picture of an arc, but this is it.If you get a tiny spark that barely will arc you have a bad transformer (sorry).
If you get nothing at all you may have a bad trans or better, a bad switch or cord.
UN PLUG it now!
If you suspect a bad switch, after un plugging, remove the small cover around the switch, unwire the 2 switch wires and wire the 2 wires that they connected to together.
Be sure to put a wire nut back on this connection.
Plug it in.
Now try the arc test again.
If you get a good arc, your switch was bad.
No arc, bad trans or bad cord.
You can check the cord for continuity with a test light. Be careful.
Transformers can be purchased from sign companies but can be pricey, friendly beer distributors can help get you one or point you in the right direction.
Ebay is a good source for both new and used transformers, search under neon transformer, sign transformer, neon power supply or tesla coil. You can also search out the brand names such as Franceformer. Just be sure you are buying a working transformer, watch for terms like "I don't know anything about this" or "as is".
As long as the input voltage (120v or 240v) and the output voltage (4,000v or 5,000v) and the output amperage (20ma or 30ma) is the same as your transformer, it will work. If it's a different size or style you may have to drill holes or whatever, but it will power the sign correctly. All this assumes the trans on your sign was the right one in the first place.
