Eaton’s Crouse-Hinds Business
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LED fixture for Ex area
Dimitri Dini
Product Line Manager LED
© 2013 Eaton All rights reserved.
• IT and data centers
• Oil and gas,
mining, industrial
• Electric utility
• Commercial
• Institutional
• Government
• Alternative energy
• Residential
• Machinery OEMs
Electrical Sector overview
Solutions for the
entire power system
Power distribution
and circuit
protection
Backup
power
protection
Lighting
and
security
Control
and
automation
© 2014 Eaton All rights reserved.
Structural
and
wiring devices
Solutions for harsh
and hazardous
environments
2
Engineering
services
2
Eaton’s Crouse-Hinds Business
Fit issue with
Syracuse, NY Text
(size 14 currently)
Syracuse, NY Headquarters and one
of 35 global facilities today
•
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
Preferred Solution for Engineering Safety & Productivity for 115 Years
© 2014 Eaton All rights reserved.
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For Oil and Gas, we are the global electrical leader in
upstream, midstream, and downstream environments
© 2014 Eaton All rights reserved.
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Our Product Lines Deliver Safety and
Reliability When It Matters Most
Explosive vapors and dusts
Corrosion
Moisture
© 2014 Eaton All rights reserved.
Extreme Temperatures
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Industry-leading, global LED Portfolio:
Eaton’s Crouse Hinds Business
IHB LED
EV LED
EVLL LED
Vaporgard LED
VMV LED
FMV LED
LL48LED
eLLK LED
LPL LED
EV35
AB05LED
ENDURE LED
PVM LED
N2LPS LED
EX-LITE LED
PFM LED
PFM 25K LED
P2L LED
Confidential
© 2013 Eaton. All rights reserved.
6
Do you know that…
... the light from LED is cold
You can obtain color temperatures ranging from warm
white (< 3000 K) to daylight (>6000 K), and can be
decided before LED production start
Confidential
© 2013 Eaton. All rights reserved.
7
Color Temperature Vs Color Rendering
• 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
Confidential
© 2013 Eaton. All rights reserved.
8
LED Color Temperature
Warm White LED
HPS
Cool White LED
3000k CCT
2000k CCT
5600k CCT
CRI 82
CRI 22
CRI 65
Color temperature refers to the degree of
yellowness or blueness in hue of illumination
Confidential
© 2013 Eaton. All rights reserved.
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9
Do you know that…
... the light from LED is blue.
The light coming from the led is white, producing
all wavelengths of the visible spectrum
Confidential
© 2013 Eaton. All rights reserved.
10
Do you know that…
... LEDs do not attract insect.
Insect are attracted from UV and blue light. Even if
led do not produce UV, they still emit blue light, so
they still attract insects.
Confidential
© 2013 Eaton. All rights reserved.
11
Do you know that…
... LEDs do not produce heat.
Even if very efficient, leds still produce heat, but
on the backside
Confidential
© 2013 Eaton. All rights reserved.
12
Do you know that…
... LEDs damage paintings.
Due to the UV-free emission, LED are even
suggested for illuminating modern painting
Confidential
© 2013 Eaton. All rights reserved.
13
Do you know that…
... LEDs are dangerous for the eyes
Leds are as dangerous as any other sources
Confidential
© 2013 Eaton. All rights reserved.
14
Do you know that…
... LEDs are expensive
True, but the payback can be very fast.
Cheaper doesn‘t mean better.
Confidential
© 2013 Eaton. All rights reserved.
15
Why LED?
USEFUL LIFE
•
Economic life can range anywhere between 60K to 170K hours or 7 to 20 years of maintenance free safe operation
ENERGY EFFICIENCY
•
LED consumes on average 50% less energy than HID and 85% less than incandescent
START / RESTART TIME
•
Nanoseconds versus > 10 min (HID)
SWITCHING CYCLE
•
As many switching cycle as wanted, without reduction of lifetime or spontaneous failure
LIGHTING QUALITY
•
No wasted light. LED is directional with focused lighting in a target workspace
ENVIRONMENTAL BENEFITS
•
Zero disposal costs, no mercury, no UV or near-IR
MAXIMUM SAFETY & ECONOMIC IMPACT
LOWEST TOTAL COST OF OWNERSHIP
© 2013 Eaton. All rights reserved.
16
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
© 2013 Eaton. All rights reserved.
17
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
© 2013 Eaton. All rights reserved.
18
Application Example 1 –
Oil & Gas Refinery
Customer Challenge - Looking for vibration
resistant rugged low maintenance lighting
solution on its catalytic cracking unit. Relamping existing 400w HPS units due to
vibration annually required building scaffolding
& 3 week of electrician work to replace
HID/HPS fixtures.
Solution – 40 Crouse Hinds Champ VMV11L
LED Light fixtures
Results –
•
Elimination of maintenance labor for
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
© 2013 Eaton. All rights reserved.
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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
© 2013 Eaton. All rights reserved.
20
Portable lighting
© 2012 Eaton Corporation. All rights reserved.
LED Hand Lamp for Zone 0
Ex-Lighting System TX/CX 40 & TX/CX 20
Application:
Gas-Ex Zone 0, 1 and 2
•
For inspection and maintenance works under extreme
ambient conditions
Advantages:
•
High Light Output with 3 W Power LED
•
Permanent maintenance free battery
•
Galvanic power transfer in Ex-Zone 1
•
High Ingress Protection (IP 67)
•
Deep discharge protection
•
Automatic function test
Feature:
•
Emergency function in combination with charger
Confidential
© 2013 Eaton. All rights reserved.
22
LED Hand Lamp for Zone 1 and 21
Ex-torch Stabex Mini LED / Stabex HF LED
Application:
•
Gas-/Dust-Ex Zone 1, 21, as well as 2 and 22
•
Stabex HF LED also for Zone 0 released
•
Inspection and Maintenance work
Advantages:
•
High ligh output with long operating time
•
Shock and vibration resistant
•
Maintenance free, no change of a lamp
•
High Ingress Protection IP 66
•
Scratch resistant glass
Confidential
© 2013 Eaton. All rights reserved.
23
New: SEB10 LED
•
Gas-Ex Zone 1/2, Dust-Ex-Zone 21/22
•
Emergency funtion in charger LG 443
Features:
•
2 LED-lens system (Search and Worklight)
•
Lithium-Iron-Phosphate battery
•
Impact and vibration resistant
•
High-Power LEDs with approx. 5 x higher
lumen output compared to halogen lamp
•
Searchlight with boost switch to increase
light output shortterm to 150%
Confidential
© 2013 Eaton. All rights reserved.
24
LED Emergency & EXIT
Lights
© 2012 Eaton Corporation. All rights reserved.
LED Escape sign luminaires
Ex-Escape sign luminaires EXIT
Also as
EXIT2 for
Zone2
Application:
• Gas-/Dust-Ex Zone 1, 21, as well as 2 and 22
• Marking of escape routes and exits in hazardous area
Advantages:
• Polycarbonate enclosure
• High Ingress protectionIP 66
• Easy cable termination with spacious connection area
• Wide voltage range 110 - 277 V
Features:
• Available as battery back-up version with internal battery
•
with monitoring function.
• Optional with CG-S-Module for connection to CEAG-Central
•
battery system
• Wide range of legends and pictograms
Confidential
© 2013 Eaton. All rights reserved.
26
LED Escape sign luminaires for Zone 1 and 21
Ex-Escape sign luminaires Ex-Lite
Application:
• Gas-/Dust-Ex Zone 1, 21, as well as 2 and 22
• Marking of escape routes and exits in hazardous area
Advantages:
• Robust light alloy enclosure with mineral glass cover
• High Ingress protection IP 66
• Spacious cable connection
• Wide voltage range 110 - 277 V
Features:
• Available as battery back-up version with internal battery
with monitoring function.
• Optional with CG-S-Module for connection to CEAG-Central
battery system
• Wide range of legends and pictograms
• Option for battery back-up for -40°C
Confidential
© 2013 Eaton. All rights reserved.
27
ELLK 92 LED 400/800
Zone 1,2 & Zone 21,22
© 2012 Eaton Corporation. All rights reserved.
eLLK LED
Primary Applications
•
Indoor or outdoor areas to retrofit existing fluorescent fixtures
Luminaire Models
Model
Equivalent Light
Output
eLLK LED 400
2X18W Fluorescent
eLLK LED 800
2X36W Fluorescent
Energy Savings
Up to 20%
Certification and Compliances
•
Ex II 2 G Ex de mb IIC T4 Gb
•
Ex II 2 D Ex tb IIIC T80 °C Db IP66
•
BVS 09 ATEX E 034
•
Ex de mb IIC T4 Gb/ Ex tb IIIC T80 °C Db
•
IECEx BVS 09.0033
Design Features
Electrical Ratings
•
Voltages:110-254VAC, 110-250VDC, 50/60 Hz
•
Input Power: 2X13W, 2X26W
A.
High output - iIluminance equivalent to related
fluorescent tubes at measurement plane
B.
Non metallic design - Glass fiber reinforced
polyester construction
C.
Retrofits to existing ELLK / NLLK fixtures with
existing EVG97 ballast or as a complete unit
D.
Minimize glare by indirect emission via inbuilt
reflector
Confidential
© 2013 Eaton. All rights reserved.
29
Safety Benefit
Installation: eLLK 92 linear LED
• eLLK 92 LED module
retrofits to the existing eLLK
fluorescent housing by
connecting to the pins and
existing ballast
• Easy and fast installation
with no ballast replacement
or electrical wiring
Confidential
one-ha
© 2013 Eaton. All rights reserved.
30
Safety Benefit
Lighting Quality: Glare Reduction
Crouse-Hinds eLLK LED
Indirect light emission => LED
via reflector
The lighting standard EN
12464-1 specifies requirements
relating to glare
• Prevents glare effect of the
LED light sources
• No multi-shadowing
A light intensity of > 30 kcd/m² is
not permissible and is hazardous
= physiological glare
Confidential
one-h
© 2013 Eaton. All rights reserved.
31
®
Champ VMV LED
Luminaire
Zone 2 & Zone 21,22
Class I, Div. 2
© 2012 Eaton Corporation. All rights reserved.
Led Fixture System Efficacy
Thermal
management
LED
•
Color
Temperature
•
Temperature
(Tj)
•
•
Optics
Driver
Thermal
Losses
(higher Tj)
•
Optical
Losses
•
Driver
Losses
Drive Current •
-10-15%
•
-10-30%
•
-10-50%
100 lm/W
85 lm/W
80 lm/W
70 lm/W
Luminaire
=
System
Efficacy
Fixture Efficacy = lumens/watt including optics, thermal & driver losses
Confidential
© 2013 Eaton. All rights reserved.
33
Champ VMV LED Luminaires
Primary Applications
• General high bay thru low bay illumination
Luminaire Models
Model
Equivalent HID Output
VMV3L
70W-100W
VMV5L
100W-150W
VMV7L
150W-175W
VMV9L
250W-400W
VMV11L
250W-320W
VMV13L
320W-400W
VMV17L
400W-600W
VMV21L
600W-750W
VMV25L
750W-1000W
Energy Savings
Up-to 77% reduction in
energy costs and 60,000
hours of continuous
operation at 55ºC !
Design Features
A.
Modular design for retrofit and new construction
Options and Accessories
B.
Safe, reliable, heat transfer
•
Quick Clip
C.
Temperature range from -40°C up to +55°C
•
Polycarbonate lens
D.
High efficiency, long life drivers
•
Several top hat
E.
Type 4X, IP66 rated
•
Trunnion mount
F.
Custom Optics (Type I, III & V) maximize light
distribution and intensity
G.
Lever-lock connectors and 3 pole terminal block
Confidential
© 2013 Eaton. All rights reserved.
34
Champ VMV LED Luminaires
Certification and Compliances
•
Class I, Division 2, Groups A,B,C,D
•
Class I, Zone 2, nA nR
•
Class II, Groups E,F,G
•
Class III
•
Zone 21, 22
•
UL844; UL1598; UL1598A
•
cUL listed to CSA C22.2 No. 137
•
Type 4X, IP66
•
IECEx/ATEX certifications
•
DesignLights Consortium® approved for select models
Electrical Ratings
• Voltages: 100-277VAC, 347-480VAC (option),
108-250VDC (option)
dual AC/DC driver for 13L up to 25L
• Input Power: 41W, 67W, 94W, 114W, 130W, 168W, 196W,
232W
Confidential
© 2013 Eaton. All rights reserved.
35
Custom Optics
Custom Optics
designed for discrete
LED power emitters
• Type V Standard
• Type I & III Options
Domed Lens for higher
optical efficiency
Type I
Type III
Type V
Confidential
© 2013 Eaton. All rights reserved.
36
Optics Options Overview
Type 1
Type 3
Applications
•
Mining conveyer belts
•
Aisle way & Hallways
•
Type 5
Applications
•
Narrow crosswalks or passages
with wall mounted fixtures
Catwalks & walkways
•
Tunnels with wall mount
•
Ramps & loading docks
•
•
Tunnels with overhead mounts
Wall or stanchion mount requiring
180° forward throw beam patterns
Applications
•
Pendant, ceiling or stanchion
mount overhead building
mounts
•
Processing mills, industrial
plants, large buildings,
warehouses etc
Custom LED Board Optics Designed To Meet A Variety Of End Use Applications
Confidential
© 2013 Eaton. All rights reserved.
37
Photometric Comparisons vs Metal Halide
175w MH
vs
VMV7L
TYPE I OPTICAL PATTERN
0.49 avg FC @ 18ft
•
Higher delivered average footcandles (0.58 vs 0.49)
•
Longer coverage by approximately 5-7ft on either side
•
Better uniformity (lower max/min FC ratio)
Type III
•
Reduction in light loss behind the fixture by 50%
•
True IES forward through Type III beam pattern
0.61 avg FC @ 18ft
TYPE V OPTICAL PATTERN
0.47 avg FC @ 18ft
Type I
0.58 avg FC @ 18ft
TYPE III OPTICAL PATTERN
0.59 avg FC @ 18ft
VMV LED Advantages
Type V
•
Higher delivered average FC (0.68 vs 0.47)
•
Better uniformity (lower max/min FC ratio)
0.68 avg FC @ 18ft
Confidential
© 2013 Eaton. All rights reserved.
38
Custom Drivers & Electrical Protection
Lever lock connectors for a
failsafe connection between
drivers, LEDs & mains
supply (No Wire Nuts)
Retrofit To existing
Crouse-Hinds HID
Champ Top Hats
Custom 50W Drivers
with PF>0.95 @ & THD
< 15% @ 277VAC
Standard 3 Pole Terminal
Block for ease of wiring &
installation
Single Piece Heat Sink
& LED Assembly
Design
• No external transformer needed for 347-480VAC option
Confidential
© 2013 Eaton. All rights reserved.
39
Economic Life
Fixture Life & Years Of Maintenance Free Operation
Ambient
Temp
L70*
LED Life
(Hrs)
F10
Driver
Life (Hrs)
F10
Fixture
Life (Hrs)
# of Yrs @
24 hrs
usage
# of yrs @
12 hrs
usage
25ºC
453,000
172,060
172,060
20
39
55ºC
417,000
60,000
60,000
7
13
• L70 – Time at which fixture has 70% of its initial output
• F10 – time at which 10% of the product will fail
Life (Hours Of Operation)
Fixture Life (Economic vs Rated)
200.000
160.000
Economic
120.000
Life
80.000
40.000
Rated Life
0
25C
30C
35C
40C
45C
Economic life can
range anywhere
between 60K to 170K
hours or 7 to 20 years
of maintenance free
safe operation
55C
Fixture Life (Hrs)
Confidential
© 2013 Eaton. All rights reserved.
40
Improved Temperature Codes
Product Family
Champ VMV
3L, 5L, 7L, 9L and 11L
Driver Type
UNV1 (100-277VAC)
VDC (108-250VDC)
UNV34 (347-480VAC)
13L, 17L
21L, 25L
UNV1 (100-277VAC)
VDC (108-250VDC)
UNV1 (100-277VAC)
VDC (108-250VDC)
Simultaneous
CL. I DIV.
CL. II DIV. Presence CL. I
Ambient 2/ZN. 2
Zone 21
1
DIV. 2, CL. II
nA, nR
DIV. 1
40°C
T6
T5
T3C
T72
55°C
T5
T4A
T3B
T87
40°C
T4
T5
T3C
T70
55°C
T4
T4A
T3A
T85
40°C
T6
T5
T4A
T66
55°C
T5
T4A
T4A
T81
40°C
T6
T5
T4A
T71
55°C
T5
T4A
T4A
T86
•
Single fixture construction meeting both NEC & IEC
certifications.
•
T5/T6 temperature codes @ 55°C/40°C ambient for
standard 100-277VAC fixtures
Confidential
© 2013 Eaton. All rights reserved.
41
Look behind the datasheet !
Excessive thermal paste
between LED board and
housing
Excessive thermal paste
between LED board and
housing
Confidential
© 2013 Eaton. All rights reserved.
42
®
Champ FMV LED
Floodlight
Zone 2 & Zone 22
Class I, Div. 2
© 2012 Eaton Corporation. All rights reserved.
Champ® FMV LED Floodlight
Primary Applications
• Indoor and outdoor area/flood lighting
Luminaire Models
Model
Equivalent Light
Output
FV5L
100W-150W
FMV7L
150W-175W
FMV9L
175W-250W
FMV11L
250W-320W
FMV13L
320W-400W
Energy Savings
Up to 62%
Certification and Compliances
• Class I, Div. 2, Groups A,B,C,D •
•
• Class I, Zone 2 & 22
•
• Class II, Groups E,F,G
Design Features
UL844; UL1598; UL1598A
A.
Versatile Design for wide range of mounting
heights & light levels
B.
Rugged heat sink for a temperature range
of -30ºC to +55ºC
CSA C22.2 No. 137
IECEx UL 11.0054X
• Class III
•
Ex II 3 G Ex nA II
• Type 4X, IP66
•
EN60079-0:2006, EN60079-15:2006
C.
High lumen output
•
Ex II 3 D tC A22 IP66
D.
•
IEC60079-31: 2008
Full-frame yoke utilizing SFA6 slipfitter
adaptor & SWB6 wall mount bracket for new
or retrofit applications
Electrical Ratings
• Voltages: 100-277VAC, 347/480VAC, 108-250VDC
• Input Power: 64W, 94W, 126W, 149W, 179W
Confidential
© 2013 Eaton. All rights reserved.
44
Champ® FMV LED Floodlight
Heat sink (-30c to +55c) with
thick rugged walls to keep driver
and LED at low operating
temperatures
High efficiency drivers & LED
arrays for up to 13000 lumen light
output for mounting heights up to
40ft
Concealed wiring and
driver housing
SFA6
Slipfitter
adaptor for
pole mount
installations
Optics specifically designed for
7x6 NEMA beam pattern
(138degH x 119degV)
Yoke Mount with 2
bolt hole for stable and
flexible installation
Confidential
© 2013 Eaton. All rights reserved.
45
FMV LED Illuminance (Isofootcandles)
Champ FMV 11L
Competition
FMV has a true flood light distribution pattern of 7x6 with better uniformity,
coverage and average foot candle levels
Confidential
© 2013 Eaton. All rights reserved.
46
Confidential
© 2013 Eaton. All rights reserved.
47