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© 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
3 © 2014 Eaton. All Rights Reserved..
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)
4 © 2014 Eaton. All Rights Reserved..
For Oil and Gas, we are the global electrical leader in upstream, midstream, and downstream environments
5 © 2014 Eaton. All Rights Reserved..
Our Product Lines Deliver Safety and Reliability When It Matters Most
Explosive vapors and dusts
Moisture Extreme Temperatures Corrosion
© 2014 Eaton. All Rights Reserved..
LED Technology Vs Traditional Lighting
7 © 2014 Eaton. All Rights Reserved..
• 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
8 © 2014 Eaton. All Rights Reserved..
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
9 © 2014 Eaton. All Rights Reserved..
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
10 © 2014 Eaton. All Rights Reserved..
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
11 © 2014 Eaton. All Rights Reserved..
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
12 © 2014 Eaton. All Rights Reserved..
• 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
13 © 2014 Eaton. All Rights Reserved..
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
14 © 2014 Eaton. All Rights Reserved..
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
15 © 2014 Eaton. All Rights Reserved..
LED Technology Projection (DOE 2012
LED Efficiency improvements
are outpacing projections
and expectations for the
foreseeable future
© 2014 Eaton. All Rights Reserved..
Myths & Misconceptions – LED Lighting
17 © 2014 Eaton. All Rights Reserved..
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
18 © 2014 Eaton. All Rights Reserved..
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
19 © 2014 Eaton. All Rights Reserved..
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
20 © 2014 Eaton. All Rights Reserved..
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
21 © 2014 Eaton. All Rights Reserved..
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
© 2014 Eaton. All Rights Reserved..
Benefits & Enabling Design Features
Environmental, Operational & Safety
23 © 2014 Eaton. All Rights Reserved..
• 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
24 © 2014 Eaton. All Rights Reserved..
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 $$
• Utility Rebate
• Material Reduction Costs **
• One Time Tax Savings
** Circuit Size, wiring, panel boards
Operational Benefits
25 © 2014 Eaton. All Rights Reserved..
SAFETY Beyond Economic
Impact $$
Maintenance Free
Operation
Lower Temperature
Codes
Vibration, Corrosion,
Dust & Water Resistance
Lighting Quality
Electrical Protection &
Reliability
Installation
Safety Benefits
26 © 2014 Eaton. All Rights Reserved..
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
27 © 2014 Eaton. All Rights Reserved..
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
28 © 2014 Eaton. All Rights Reserved..
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)
29 © 2014 Eaton. All Rights Reserved..
• 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
30 © 2014 Eaton. All Rights Reserved..
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
31 © 2014 Eaton. All Rights Reserved..
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
32 © 2014 Eaton. All Rights Reserved..
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
33 © 2014 Eaton. All Rights Reserved..
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
34 © 2014 Eaton. All Rights Reserved..
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
35 © 2014 Eaton. All Rights Reserved..
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
36 © 2014 Eaton. All Rights Reserved..
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
37 © 2014 Eaton. All Rights Reserved..
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
38 © 2014 Eaton. All Rights Reserved..
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
© 2014 Eaton. All Rights Reserved..
Application Examples & Installations
40 © 2014 Eaton. All Rights Reserved..
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
41 © 2014 Eaton. All Rights Reserved..
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
42 © 2014 Eaton. All Rights Reserved..
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
© 2014 Eaton. All Rights Reserved..
Summary
44 © 2014 Eaton. All Rights Reserved..
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
45 © 2014 Eaton. All Rights Reserved..
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
46 © 2014 Eaton. All Rights Reserved..