led technology & customer value ledhead

© 2014 Eaton. All Rights Reserved..

LED Lighting For Harsh & Hazardous Locations

Eaton’s Crouse-Hinds Business

LED Lighting Technology & Customer Value

2 © 2014 Eaton. All Rights Reserved..

Agenda

• Eaton’s Crouse-Hinds Business

• LED Technology Overview

• LED vs. Traditional Lighting

• How LED works

• Myths of LED

• LED Benefits- Environmental,

Operational, Safety

• Success Stories & References

• Selection Criteria


Company Overview

Syracuse, NY Headquarters and one

of 35 global facilities today

Preferred Solution for Engineering Safety & Productivity for 115 Years

• World’s leading provider of electrical

and instrumentation products for

harsh and hazardous environments

• Founded in 1897 in Syracuse, New York

• Portfolio of 100,000+ products

• 60% of Revenue Outside US

• 4,600 employees worldwide

Fit issue with

Syracuse, NY Text

(size 14 currently)


For Oil and Gas, we are the global electrical leader in upstream, midstream, and downstream environments


Our Product Lines Deliver Safety and Reliability When It Matters Most

Explosive vapors and dusts

Moisture Extreme Temperatures Corrosion


LED Technology Vs Traditional Lighting


• Lighting consumes 19% of all electricity in the world

• Approximately 67% of all lighting currently installed is based on older, less energy

efficient technology developed before 1970

• The mercury from one fluorescent bulb can pollute 6,000 gallons of water beyond

safe drinking levels & contaminate a 20 acre lake forever

• ~ 500,000 injuries & accidents are a result of people falling from ladders

• Value of LEDs becomes exponentially important in hazardous environments

Key Issues

Safety

Harsh environments

Rising energy prices

Maintenance expenses

Lifecycle costs

Environmental pollution

Lighting Facts


Customers Prefer LED Over Traditional Light Sources Due To Overall Safety, Lower

Cost Of Ownership & Superior Lighting Quality

LED Fluorescent Induction HID Incandescent

Useful Life

Energy Efficiency

Start/Restart Time

Lighting Quality

Total Cost of

Ownership

Average Poor Strong

Light Sources Compared To LED


Difference With LED Lighting Benefits

• Efficiency Up to 150 lumens/watt

• Directional No wasted light, any pattern

possible

• Long Lifetime >60,000 hours to 70%

Lumen Maintenance (L70)

• Start Instantly Nanoseconds vs. > 10

min re-strike (HID)

• Environmentally Friendly No Hg, Pb,

heavy metals

• Infinitely Dimmable, Controllable

Increased power savings & lifetime

• Love Cold Temperatures Cold start

capable

• Low Temperature – Run cooler than

HID/HPS

Visible Light

Heat

Lens

LED Chip or Die

with Phosphor

coating

Thermal

Heatsink

Bond Wire

Outer

Package

Cathode

Lead Silicon

Submount

Solid State Lighting –

P-N junction semiconductor device with a

die & phosphor coating.

• No Ballasts

• No Glass bulbs

• No Filaments

• No Pressurized gases

• No toxic chemicals


Candela • Historically, candelas are roughly equal to the intensity of light emitted by one candle. Technically defined as the

luminous intensity in a given direction.

Illuminance (Lux/Footcandles) • Intensity of the light output for a given lamp within a luminaire • Represented as Lumens Or Light Output Per Square Foot • This is measured by footcandles or lux

Lumens • Absolute light output emitted by a luminaire

• Photopic Lumens is the amount of light registered by human eye and is measured by standard light meters • Scotopic Lumens represents the sensitivity of the eye under typical interior lighting conditions and cannot

measured directly by a light meter

Efficacy • Measure of efficiency at the light source. Calculated as the ratio of lumen emitted per watt of energy

• 2

Lighting Definitions

Source: Illuminating Engineering Society of North America


How LEDs Make White Light

White Light Is Produced When Blue Light Is Passed Through

The Phosphor Coating Or When Colored Light From RGB Chips

Is Mixed In An Appropriate Ratio

Source – DOE Solid State Lighting


• Color Temperature (CCT)

• Refers to the degree of yellowness or blueness in hue of illumination

• Measured in degrees Kelvin

• Color Rendering (CRI)

• The ability of a light source to represent true colors in objects

• Based on a scale of 0 to 100

• The higher the number the more vibrant the color

• LED Color Consistency

• Remains stable over time

• Quality across multiple fixtures

• Tighter binning control is a key enabler

Two Main Factors In Measuring Color: Quality & Appearance

Difference Color Temperature Vs Color Rendering


LED Color Temperature

13

Color temperature refers to the degree of

yellowness or blueness in hue of illumination

HPS

2000k CCT

CRI 22

Cool White LED

5600k CCT

CRI 65

Warm White LED

3000k CCT

CRI 82


Energy Efficiency Comparison

Light Type Data Sheet

lm/W Usable* lm/W

Lifetime (hrs)

Incandescent 17 10-18 3k

Halogen 20 12-20 10k

Pulse Start Metal Halide 70 50 - 90 5k-15k

T12 fluorescent 60 45-50 20k

High-pressure sodium 91 50 -90 20-24k

T8 fluorescent 74 55-60 20k

Low-pressure sodium 120 65-70 18k

T5 fluorescent 107 96 30k

Best-in-Class Power LED 150 100 > 60k (L70)

* Usable lm/w – Based on Delivered Lumens

LEDs rank the best in terms of usable luminaire level efficacy and lifetime


LED Technology Projection (DOE 2012

LED Efficiency improvements

are outpacing projections

and expectations for the

foreseeable future


Myths & Misconceptions – LED Lighting


LED Thermal

management Optics Driver Luminaire

• Color

Temperature

• Temperature

(Tj)

• Drive Current

• Thermal

Losses

(higher Tj)

• -10-15%

• Optical

Losses

• -10-30%

• Driver

Losses

• -10-50%

100 lm/W 85 lm/W 80 lm/W 70 lm/W System

Efficacy =

Fixture Efficacy = lumens/watt including optics, thermal & driver losses

Myth: System Efficacy Explained


Myth: Rated vs. Economic Life Explained

Economic life defined as

• the period of operation before

catastrophic failure during which

fixture does not require any

service

• It is estimated by LED & driver life

both. The fixture life is dependent

upon the weaker of the two –

Driver or Power supply

Rated Life- is defined as the

maintenance free life of an LED

fixture under worst case operating

conditions i.e 24/7 operation @ 55C

ambient temperature

Fixture Life & Years Of Maintenance Free Operation

0

40,000

80,000

120,000

160,000

200,000

25C 30C 35C 40C 45C 55C

Lif

e (

Ho

urs

K)

Fixture Life (Econ. Vs. Rated)

Economic

Life

Rated Life

60,000

172,000


Myth: Lumens vs. Footcandles Explained

HID, Incandescent, fluorescent

Lighting is omnidirectional

LED is directional with focused

lighting in a target workspace

• Foot-candles/lux is the true measure of a light fixture’s ability to effectively illuminate

a targeted area NOT raw lumens

• Directional nature of LEDs makes them suitable for use with custom optics


Third Party Performance Testing & Validation - LM79 Report

Defines how to measure photometry

and chromaticity for LED lamps and

fixtures

Fixture measured at 25°C ambient,

after thermal stabilization

Provides Integrating Sphere,

Photometric & Electrical Test Reports

on various fixture attributes such as

efficacy, wattage, CRI, CCT, power

factor, THD, zonal lumen spread etc

IESNA, Energy Star & Design Lights

Consortium accepted

DOE approved test labs such as LTL,

Intertek are equipped to perform

certification & testing


LED Lumen Maintenance Testing – LM80 & TM21

IESNA & Energy Star approved method for

measuring lumen depreciation of LED

packages

Does not cover measurement of luminaires

or provide estimation of life of complete

LED fixture

L70 is the point at which the LED’s have

lost 30% of their initial lumen output

Measurements of a sample of 15 or more

LEDs is taken at 1K intervals at 25C, 55C

& 105C ambient temperatures

6K hours of minimum testing for reporting

> 36K hrs of life & 10K hours of testing for

reporting > 60K hrs of life

TM21 calculator utilized to estimate L70

life of a LED package at a particular case

(insitu) temperature & drive current


Benefits & Enabling Design Features

Environmental, Operational & Safety


• No filaments like incandescent lamps

• No electrodes like gas discharge lamps

(HPS, MH, and fluorescent)

• No mercury in the light source

• Negligible UV or infrared radiation in visible

light distribution spectrum

• Zero disposal costs

• Reduction in carbon footprint

• No light pollution – Dark Sky compliant

design

• Visible spectrum is wildlife friendly

supporting sea turtles, etc…

Environmental Benefits


Economic Value $$$

Direct Energy

Savings($/yr HVAC

Savings $/yr

Labor Savings

$/yr

Lamp & Ballast

Savings $/yr

Fixed Costs*

$/yr

Downtime Reduction

$/yr

One Time Material

Reduction ($) **

One Time Utility

Rebate ($)

One Time Tax Rebate

($)

Economic Impact to Replace

One 250w MH fixture with LED

Annual Recurring Savings $$

• Energy

• Labor

• HVAC

• Lamp/Ballast

• Fixed costs*

• Downtime opportunity cost

* Rental Equipment, Lifts, Scaffolding

One Time Benefit $$

• Utility Rebate

• Material Reduction Costs **

• One Time Tax Savings

** Circuit Size, wiring, panel boards

Operational Benefits


SAFETY Beyond Economic

Impact $$

Maintenance Free

Operation

Lower Temperature

Codes

Vibration, Corrosion,

Dust & Water Resistance

Lighting Quality

Electrical Protection &

Reliability

Installation

Safety Benefits


Maintenance Savings Deep Dive: LED Lighting In Hazardous Locations

Permit Paperwork Job Safety Analysis

Driving to jobsite Getting Equipment

Getting to fixture Fixture Setup

HID/FL Disposal Closing Permit

Chevron Example:

% of time using

Ladders – 60%

Man Lift – 20%

Bucket Truck – 15%

Scaffolding* – 5%

Time to build Scaffolding

• 10ft = 16 hrs

• 20ft = 20 hrs

Avg Time To Replace

Light Fixture = 5 Hours

P Hours

Q Hours

R Hours

S Hours


Safety Benefit Maintenance-Free: Economic Life

Crouse-Hinds New Champ LED Economic Life Example

Ambient

Temp

L70* LED

Life (Hrs)

Driver

Life (Hrs)

Fixture

Life (Hrs)

# of Yrs

@ 24 hrs

usage

# of yrs

@ 12 hrs

usage

25C 453,000 172,060 172,060 20 39

30C 469,000 143,383 143,383 16 33

40C 501,000 107,537 107,537 12 25

55C 417,000 60,000 60,000 7 13

* L70 – Time at which fixture has 70% of its initial output

0

40,000

80,000

120,000

160,000

200,000

25C 30C 35C 40C 45C 55C

Lif

e (

Ho

urs

Of

Op

era

tio

n)

Fixture Life (Economic vs Rated)

Fixture Life (Hrs)

Economic Life

Rated Life

Economic life can range

anywhere between 60K to

170K hours or 7 to 20 years

of maintenance free safe

operation


Superior Temperature Performance T5 @

65C & T6 @ 55C ambient condition

Superior

designed

flame paths

optimize

protection

Robust heat sink design

ensures long life in

extreme environments

Safety Benefit Lower Temperature Codes

Crouse Hinds EVLL Div 1 Fixture Crouse Hinds Champ Div2/Zone2 Fixture

• Single fixture construction meeting

NEC & IEC certifications.

• T5/T6 temperature codes @ 55C/40C

ambient for UNV1 fixtures

Product

Family

Champ VMV

Ambient

CL. I DIV.

2/ZN. 2

nA, nR

Zone

21

40C T6 T72

55C T5 T87

40°C T4 T70

55°C T4 T85

40°C T5 T60

55°C T4 T75

3L, 5L, 7L, 9L

and 11L

RL,GL,BL,AL UNV1 (100-277VAC)

Driver Type

UNV1 (100-277VAC)

VDC (108-250VDC)

UNV34 (347-480VAC)


• Heat Sinking in a LED system is done @

• LED package substrate level

• LED printed circuit board level (Thermal pads)

• LED fixture body over PCB & drivers in form of

finned structure to increase heat transfer surface

• Why is Heat Sinking Important?

• Reduction in lumen depreciation & color shift of

LED over time

• Obtain lower T codes for fixtures used in

explosive environments

Finned Heat Sink

Thermal Management - Longer LED Life, Color Stability & Lower T Codes

Junction Temperature (Tj) – within the LED die is

affected by drive current, thermal path & ambient

Safety Benefit Maintenance-Free: Thermal Management


Safety Benefit Lighting Quality

Benefits • Bright crisp white lighting & natural color • Improved workplace illumination • Consistency in color • Minimize # of fixtures • Accident avoidance • Downtime avoidance • Instant ON/OFF & restrike • Instant start in cold -40C • Minimize Glare

Features • Higher foot candles delivered to work plane • More coverage • More uniformity • Consistency in color • Minimize light spill & max/min Fc ratio

Design Drivers • Custom optics – Type I, III & V • Lens design & material • LED component selection • Indirect radiation via reflector


Type 1

Type 3

Type 5

Applications

• Mining conveyer belts

• Aisle way & Hallways

• Catwalks & walkways

• Ramps & loading docks

• Tunnels

• Narrow crosswalks or

passages with wall

fixtures

• Tunnels with wall mount

• Wall stanchion mount

with 180° forward throw

• Pendant, ceiling or

stanchion mount

overhead building

• Processing mills,

industrial plants, large

buildings, warehouses

Custom Optics For Directional & More Uniform Light Distribution By Application

Safety Benefit Light Quality: Optics

Reduction in loss

behind by fixture

by 50%

Better uniformity

Higher avg FC

Longer coverage

by 5-7 ft

Better uniformity

175w MH vs VMV7L

TYPE I OPTICAL PATTERN

TYPE III OPTICAL PATTERN

TYPE V OPTICAL PATTERN

0.58 avg FC @ 18ft 0.49 avg FC @ 18ft

0.61 avg FC @ 18ft 0.59 avg FC @ 18ft

0.68 avg FC @ 18ft 0.47 avg FC @ 18ft

Higher avg FC

Better uniformity


Custom Optics in CCH

Champ fixture designed

for discrete LED power

emitters

• Type V Standard

• Type I & III Options

Type I Type III Type V

Domed Lens for higher

optical efficiency

Safety Benefit Light Quality: Optics


Safety Benefit Lighting Quality: Glare Reduction

one-h

Crouse-Hinds eLLK LED for

Zone 1,2,21 & 22:

Indirect light emission => LED

via reflector

Prevents glare effect of the

LED light sources

No multi-shadowing The lighting standard EN

12464-1 specifies requirements

relating to glare

A light intensity of > 30 kcd/m² is

not permissible and is hazardous

= physiological glare


Benefits:

• Prevent complete loss of illumination in

critical areas

• Prevent outage from current/voltage spikes

• Reduce overheating/fire risk

• Reduced EMI interferences with

equipment/machinery

• Reduced maintenance

Features:

• Redundant drivers for multiple LED circuits

• Drivers separated from LED subassembly

• In built surge protection

• High efficiency >0.9

• Low THD < 20%

Design:

• LED drivers with step down constant

voltage &/or constant current

Safety Benefit Electrical Protection


Transformers – “Transform” incoming power to a

lower desired voltage proportional to input voltage

Power Supplies or Drivers

• Constant Voltage – produce a fixed output voltage

regardless of input voltage & convert AC to DC

• Constant Current – regulate energy passing through

LEDs by passing constant current through LED

system

• Drivers result in loss of efficiency of LED

system. Most drivers are 85%-90% efficient

with a power factor of > 0.85

• Drivers contain electronic components which

can raise temperature of LED system and

need to have an effective heat sink

• Driver redundancy & field replaceability

are key for a reliable LED system

Transformer 100V to 120V 10V to 12V

Power

Supply 100V to 120V Fixed 24V DC

Drivers isolate the LEDs from surges in incoming voltage or current

Drivers 24VDC Fixed 350mA

Power

Supply

Drivers

Led

Drivers

Safety Benefit Electrical Protection: Drivers


Benefits:

• Prevent loss of time and money during

fixture installation

• Reduce effort and stress during installation

• Minimize injury during installation

• Minimize overall labor and cost

Features:

• Wire-free connections

• Hinged support for fixture during mounting

• Backward compatibility to HID top hats

• Quick clip accessory to prevent supporting

weight of fixture

Design:

• Quick connect wirefree +ve/-ve connections

between LED & mains

• Adaptors to legacy top hats

• Common top hats between HID & LED

• Terminal blocks for plug and play wiring

Safety Benefit Installation

LED and driver housing

36

Adapter - EVSA

Common Top Hat

HID/LED

Hinged Hook,

concealed wiring

& terminal block


Safety Benefit: Protection Against Harsh Environmental & Extreme Conditions

Dust

Cold Start

Rain Marine

Vibration up to 5G

forces

Vibration Testing

Rain Testing Result: NEMA 4X, IP66, Wet & Marine Location

Result: Withstand up-to 6G 3 axis vibration

Hose Down Testing Result: UL 1598A for Marine Wet Applications

Impact Testing Result: Tempered & Shatter resistant glass lens

Cold Start Testing

Result: -40C Start up and Operating temperature

Dust Testing

Result: withstand dust ingress in 2KPa vacuum for 8 hrs

Web Links:

• PFM25L vibration video

http://www.cooperindustries.com/content/public/en/crouse-hinds/products/lighting/led_luminaires/champ_pro_pfm_series_25l_50l_led_floodlights.resources.html

../LEDHED/2013 LEDHEAD Flash Drive Oct 29-31/Videos/1310_Vibration-Test.mp4

../LEDHED/2013 LEDHEAD Flash Drive Oct 29-31/Videos/1310_Drop-Test.mp4

../LEDHED/2013 LEDHEAD Flash Drive Oct 29-31/Videos/1310_Rain-Test.mp4

../LEDHED/2013 LEDHEAD Flash Drive Oct 29-31/Videos/1310_Hose-Test.mp4

../LEDHED/2013 LEDHEAD Flash Drive Oct 29-31/Videos/1310_Dust-Test.mp4

../LEDHED/2013 LEDHEAD Flash Drive Oct 29-31/Videos/1310_Cold-Start-Test.mp4


Safety & Operational Benefits: Facility Level Monitoring & Controls

Two way

Radio

Server

Azonix

Industrial PC

Smart

Device

Panel Board

Sensing & Monitoring

Multi sensor integration in LED fixture

Wired/Wireless Mesh Network

Zigbee, Dali, PLC

Internet Cloud Integration

Two way communication between LEDs,

Panels, servers, PC & smart devices

Web Based Real Time Monitoring &

Control – Enabling a full service

solution


Application Examples & Installations


Application Example 1 – Oil & Gas Refinery

Customer Challenge - Looking for vibration

resistant rugged low maintenance lighting solution

on its catalytic cracking unit. Re-lamping existing

400w HPS units due to vibration annually required

building scaffolding & 3 week of electrician and

carpenter work to replace HID/HPS fixtures.

Solution – 40 Crouse Hinds Champ VMV11L

LED Light fixtures

Results –

• Elimination of maintenance labor for

carpenters and electricians, material &

disposal costs for HID/HPS fixtures and

ballasts resulting in an annual savings of

$40,000

• No vibration related lighting fixture failures

since Champ LEDs have been installed


Application Example 2 – Chemical Processing Plant

Customer Challenge – Retrofit existing 175w

MH fixtures with high lumen low maintenance

LED fixtures

Solution – Crouse Hinds Champ VMV5L &

VMV7L LED Light fixtures

Results

• 60-70% energy reduction. 70w LED

replacing 175w MH

• Improvement in lighting quality by

achieving more uniform foot-candle

distribution & crisp natural color lighting

• Significant reduction in labor &

maintenance costs due to 7-9 years of

LED fixture life


Installations Across Multiple Harsh & Hazardous Market Segments

Chemical

Processing Oil & Gas Drilling Heavy Industrial

Marine Mining

Installed base of 100,000+ LED fixtures in harsh & hazardous locations


Summary


LED System Selection Criteria For Harsh & Hazardous Applications

Total Cost Of Ownership – Safety, Lifetime, Efficiency, Light Quality & Installation

1. Safety (Certifications & Compliances) • Temperature rating

• NEC/IEC Hazardous location certifications

• Moisture/wet location protection

• Environmental conditions (Vapors, dusts, fibers etc.)

2. System Lifetime • LED case and junction temperature (Tj)

• Secondary system thermal management

• LED rated and economic life

3. Light Quality & Performance • Color temperature & CRI

• Lux or footcandles

• Light distribution and supporting optics

4. System Efficiency • LED package efficacy (lm/w)

• LED package lens (optics)

• Secondary system optics (reflectors)

• Driver and heat sink efficiency

5. Mounting And Installation Options


Industry-leading, Global LED Portfolio – Eaton’s Crouse Hinds Business

EV LED EVLL LED Vaporgard LED VMV LED FMV LED

PFM 25K LED

LL48LED eLLK LED LPL LED EV35 AB05LED ENDURE LED

PFM LED P2L LED PVM LED

LAL05 LED

N2LPS LED EX-LITE LED

led technology & customer value ledhead

Documents

intensity of light

traditional light sources

overall safety

wasted light

energy efficient technology

downstream environments

company overview syracuse

die phosphor coating