Tetra® Contour Light Guide Forming Instructions

General Warning

The light guide is made to use together with the light engine. Please ensure you read the installation guide and warnings of light engine before installing.

Preparation

1. Step 1: Remove Protective Film

   Remove the protective film from the light guide.

2. Step 2: Mark Length

   Mark the light guide at the required length, adding 0.5 in. (13mm) for every 16 in. (406mm) to account for shrinkage during the forming process.

3. Step 3: Cut Light Guide

   Cut the light guide to the required length using a hacksaw, chop saw (cross cut or veneer blade only), band saw, or other appropriate plastic cutting tool.

4. Step 4: Fill Channel with Bend-Aid

   Fill the entire light guide channel with the GEXNBA Silicone Bend-Aid(s) and press into place. Bend-Aid must be installed prior to heating and forming. The GEXNBA Silicone Bend-Aid is reusable.

   [Diagram Description: Shows filling the channel of the light guide with a silicone substance.]

WARNING: DO NOT heat and form the light guide with the light engine installed.

Heating and Forming

For large bends, use either an industrial oven or heating blanket. For small bends, use a heat gun.

CAUTION: Avoid direct contact between hot materials and exposed skin or combustibles. Use heat resistant gloves while heating and/or handling any hot materials.

CAUTION: DO NOT use an open flame to heat the light guide.

Option A: Large Bends

Preheat the heating equipment to 300°F (149°C). Heat light guides approximately 6-15 minutes until soft and pliable. Bend the light guide over a printed pattern, routed template, or use free-forming. A clean flat insulated surface (wood or laminated countertop) will help to prevent twisting or bowing. See the chart above for minimum bend radius guidelines.

[Diagram Description: Illustrates bending a light guide using a heat gun or oven, possibly over a template.]

Option B: Small Bends

Part 1: Move the section back and forth while rotating about the diameter until it is soft and pliable. Gently bend to the desired angle. It is recommended to use a heat-deflecting shield to distribute the heat evenly. Avoid localized overheating that may result in distortion or damage (i.e. bubbling) of the light guide.

Part 2: The workable forming time is about 2-3 minutes. The light guide must remain in the desired position until completely cooled. See the chart above for minimum bend radius guidelines.

[Diagram Description: Shows close-up of bending a light guide with a heat gun, emphasizing gentle bending and heat distribution.]

Cooling and Finishing

Allow the light guide to cool by natural convection or lightly forced cool air (i.e. fan). Remove the Bend-Aids for reuse. In order to remove any minor surface flaws, perform a light sanding using 400 grit sandpaper. Flared or deformed ends can be trimmed. The light guide is now ready for light engine installation.

NOTE: DO NOT remove the Bend-Aids until the light guide has completely cooled.

NOTE: DO NOT subject heated light guide to freezing or quenching in water.

Compliance Information

This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

This Class [A] RFLD complies with the Canadian standard ICES-005. Ce DEFR de la classe [A] est conforme à la NMB-005 du Canada.

Contact and Support

If you have any questions about these instructions or your specific application, please contact support at tetra.support@gecurrent.com.

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