Cutting Energy & Maintenance Costs with LED Lighting

… and at the same time improving light quality and reliability

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DialightSo what is an LED?

Solid-state semiconductor technology

- Smallest light source available- Mercury & lead free material (RoHS)- Silicone lens- Die- LED package- Solder pad

LEDS are the most efficient white light source

Solid state semiconductor technology with no air, glass or fragile filaments - they're the most robust and efficient light source

The die emits blue light and is coated with phosphor that absorbs a portion of the blue light and re-emits it as other colours to fill in the spectrum resulting in white light.

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DialightLED Technology – old vs new

c 20,000 hrs lifetime v >100,000 hrs

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DialightTypical white LED roadmap

Add 20-30% over next 5 years

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

High Pressure SodiumThe industry has recognised HPS as a standard due to its high efficacy and lumen maintenance, but the largest issue with it is the colour it emits, which appears to the human eye as orange and represents poor quality of light at night. This presents a significant risk in hazardous environments at night, since machine operators and maintenance workers need to quickly and easily identify coloured wires, safety plaques, liquids, objects or smoke.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

Low Pressure SodiumLPS is technically not a white light source but has been used in lighting. LPS has very high bulb efficacy (up to 200 lumens/watt) but has the worst colour quality.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

Mercury VapourMercury vapour is fairly inefficient with a bulb efficacy of about 50 lumens/watt (when phosphor coated) and has a poor CRI of up to about 50. The phosphor coating on the glass of the bulb makes it a large source size and therefore difficult to control the light distribution precisely. For these reasons, and due to the use of mercury, these lamps are not commonly used any more.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

Metal halideMetal halide is a common light source used today because of its good colour quality (85-95) and low cost. Metal halide suffers from rapid lumen depreciation and the lamps contain mercury.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

FluorescentFluorescent fittings are common light sources used today due to their high efficacy (55-100 lumens/watt) and good colour rendering (50-90). While they have good lumen maintenance they fail catastrophically at end of life and contain mercury. The source size is large because of the use of phosphors and therefore controlling the light distribution is difficult and can result in poor utilisation of light.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

CFL – Compact FluorescentCompact fluorescent (CFL) lamps have good CRIs (50-90) but mediocre efficacies (50-75 lumens/watt) and they contain mercury. The source size is large due to the use of phosphors and therefore controlling the light distribution is difficult and can result in poor utilisation of light.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

IncandescentIncandescent lamps have the highest CRI (up to 100) but the lowest efficacies (5-25). Their fragility is also an issue for industrial applications.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

InductionInduction lighting is similar to fluorescent but is an electrode-less light source and therefore has long life (over 100,000 hours). It has good CRI (50-90) and good efficacy (60-90 lumens per watt). The source size is large due to the use of phosphors and therefore controlling the light distribution is difficult and can result in poor utilisation of light.

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 150 100+

LEP – Light emitting plasmaLight emitting plasma is the newest light source technology. Being an electrode-less light source it has long life (over 100,000 hours). It also has good CRI (50-90) and good efficacy (60-90 lumens per watt).

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DialightLED vs other lighting technologies

Light source CRI Lumens/watt Lifetime in hours(x1000)

High pressure sodium 30 60-120 10-24

Low pressure sodium 5 200 10-24

Mercury vapour 50 50 10

Metal halide 70-95 60-100 6-20

Fluorescent 60-90 40-100 6-45

CFL 60-90 50-75 6-15

Incandescent 90-100 5-25 1

Induction 50-90 60-90 100

LEP 50-90 60-90 100

LED 70-90 Up to 160 100+

LEDLEDs are “full-spectrum” light sources with no gaps in the colour spectrum. They have good CRI (70-85) and the highest efficacy (up to 160 lumens/watt) of the white light sources. LEDs emit light in a hemispherical direction instead of a full spherical direction. Because the light is only directed forward, the optics can be simpler and are more efficient. LEDs are highly robust and can last well over 100,000 hours.

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DialightProblems with existing lighting technologies

Poor quality of light

Large installed base of inefficient high pressure sodium fittings

Excessive use of energy

Safety & maintenance risks

Sudden & unexpected light failures

Audible noise produced

Unlike LEDs with instant-on ability, fittings such as HID and fluorescent do not turn on instantly at full brightness and therefore are often left on when not in use.

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DialightTechnology Comparison: HPS

400W HPS Lamp Startup Colour Shift

• Efficiency - 100 lm/W• Colour quality CRI = < 30• Lumen maintenance - L70 = 16,000 hours• Longevity - bulb life = 24,000 hours

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DialightTechnology comparison: HPS

Typical makeup of bulb materialKnown Issues

• Susceptible to colour shift at end of life• Poor T-rating (of concern in hazardous areas)• Unreliable in extreme temperatures• Unable to handle extreme shock & vibration• Can only be dimmed to 50%• Long re-strike time (up to 15 mins)• Contains 30mg of mercury (400W bulb)

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DialightTechnology comparison: Metal halide

• Efficiency - 80 lm/W• Colour quality - CRI = 75• Lumen maintenance - L70 = 6,000 hours• Longevity - bulb life = 16,000 hours• Long startup times

Known Issues

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DialightTechnology Comparison: Metal halide

Typical makeup of bulb materialKnown Issues

• Susceptible to colour shift

• Poor T-rating (hazardous location issue)

• Unreliable in extreme temperatures

• Unable to handle extreme shock & vibration

• Can only be dimmed to 50%

• Long re-strike time (up to 20 mins)

• Contains 38mg of mercury (400W bulb)

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DialightRelative T-ratings of light sources

Maximum Surface Temp

CENELEC EN 50 014 IEC (Group II)

60079-8 NEC® 505

NEC 500 – Table 500.8 (B)

450°C (842°F) T1 T1300°C (572°F) T2 T2

280°C (536°F) T2A

260°C (500°F) T2B230°C (446°F) T2C

215°C (419°F) T2D

200°C (392°F) T3 T3180°C (356°F) T3A

165°C (329°F) T3B

160°C (320°F) T3C135°C (275°F) T4 T4

120°C (248°F) T4A

100°C (212°F) T5 T585°C (185°F) T6 T6

Metal Halide

HPS

LED

Temperature Classification

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DialightThe importance of LED fixture design

Thermal Design Electronic Design

• Maximise useable light

• Increase light spacing

• Improve uniformity

• Manage heat from LEDs

• Manage heat loss from driver

• Minimise conducted heat reaching driver

• Power LEDs efficiently/drive current 350MA/500/750 etc

• Implement control features

• Protect against transients in the electronics

Optical Design

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DialightMaintenance savings

• Maintenance costs up to $2,000 per lamp!• Traditional lamps often don’t reach full

expected life due to vibration, excessive heat• Hazardous areas require multiple personnel,

permitting, scaffolding• Production down time = $$$

How does maintenance savings affect payback?

Expected life

• Metal halide bulb = 2 years

• LED fixture = 10+ years

Scenario

• $1,000 / year

• (100) 153W LED High Bays replace

• (100) 480W HID High Bays

Annual Savings:

• Maintenance Savings $100,000 / year

• ~1 year payback

Maintenance savings : $100,000 / year

Hazardous location example

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DialightApplication case study: savings with rebate*

Project Overview• (140) 400W HID vs. (140) 150W LED

• Initial spend: $80,000

• Utility rebate incentive: ($48,000)

• Annual Energy Savings: ($16,000)

• Annual HVAC Savings: ($8,000)

• Annual Maintenance Savings: ($15,000)

• CO2 Reduction: 124 tons

Payback w/ Rebates = < 1 yearBaby Wipe Manufacturing Facility

*US only

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DialightApplication case study: savings on energy alone

Project Overview (136) 250W and (100) 400W HID vs. (126) 150W LED – lights in use 24/7

HID were actually drawing 280W and 430W

• Annual Energy Savings: (£42,000)

• W/sqm down from 3.85 to 1.05

• CO2 Reduction: 271 tons

Payback = 1.1 yrs on energy saving alone

Distribution warehouse for logistics companyLED lighting in foreground and HID at back

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DialightApplication case study: savings inc maintenance

Project Overview (13) 400W HID vs. (8) 172W LED – HID were actually drawing 440W

Lights in use 8 hrs per day, 5 days a week, 50 weeks a year

• Initial spend: £4320

• Annual Energy Savings: (£695)

• Annual Maintenance Savings: (£2297)

Annual maintenance of shed lighting involved cost of 2 men for one week + hire of cherry picker, cost of 13 replacement polycarbonate lenses and 4-5 lamp changes. All of this can be eliminated by using LED high bays which can be expected to last for 10 years or more.

Payback = 1.3 yrs

Bulk storage shed at port facilityLamp maintenance only possible when the

shed is empty, so many lights were often out

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DialightLighting controls and monitoring

iPhone

PLC/ DALI Wall Controller

Internet

PLC MotionSensor

HB1 HB2 HB N-1

PLCPLC PLC PLCHBN

HB1 HB2 HB N-1

PLCPLC PLC PLCHBN

PLC MotionSensor

PLC/ DALI Wall Controller

PLC MotionSensor

PLC MotionSensor

NetworkManager

iPad

Laptop

To further enhance safety, predictability and measurability, LED lighting manufacturers are introducing light systems that can be monitored remotely. These systems come with a communication device built into the fixture, integrated with the driver circuitry and the two communicate with each other. The fixtures transmit data to a central, remotely located monitoring system and have the ability to report pertinent information related to the lighting system (lumen output, energy consumption, etc).

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DialightFuture of LED technology – advanced controls

• Faster payback period / further energy reduction

• Occupancy sensor integration• Advanced dimming based on user

defined settings• Controlling individual or groups of

LED fittings to reduce wasted light• Demand response• “Smart” lumen depreciation

settings to maintain original light levels

LED technology allows for the lights to be dimmed with simple circuitry and paired with occupancy sensors to create a ‘smart’ lighting system.

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DialightFuture of LED technology: Monitoring/reporting

• Real time notifications

• Predictable energy usage

• Custom reporting based on user recs

• Zero maintenance lighting system

• Emergency fitting battery life monitoring

• Failure detection and notification

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DialightSummary

This is how LED technology compares to other lighting technologies:

- It consumes less power- It has instant-on ability- It performs better in extreme conditions- It lasts longer to reduce maintenance costs- It contains no mercury or hazardous material- It generates a better quality of light- It provides better ROI compared to conventional technologies- It’s ready for integration into ‘smart’ lighting solutions

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DialightWant to know more?

www.dialight.com

info@dialight.com

TCO calculator – try our calculator to find out what you could save by installing LED lighting.