Industrial Lighting Applications and Systems
Jerry Flauto
&
Roy Sierleja
GE Lighting Institute
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GE Lighting Institute
Industrial Applications and Systems
Special Issues and Concerns in Industrial Lighting
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Need for uniform light levels
Dirt and Heat
Cold Ambients
Inspection of small parts/finding subtle defects
Maintenance/downtime is expensive
Safety (moving parts, strobing/flickering)
Shadows
Productivity
Energy
Legislation
Environment
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GE Lighting Institute
Industrial Applications and Systems
The Landscape: Operating costs are rising !
Energy (usage and demand)
One 400W fixture , 24/7 @ $.1/kWh costs:
460W X 8760 hrs X $.1/kWh = $403/yr
Opportunity
To Save
> $189/yr
Other Issues
Labor (maintenance)
Down time
Inspection and rework
Lost time accidents
Non-Energy costs
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GE Lighting Institute
Industrial Applications and Systems
The Landscape: Legislation is eliminating many
common lighting products:
• 2008: Mercury ballasts
• 2009: Most Probe start ballasts
• 2010: EM ballasts for many T12 fluorescent lamps
• 2012 – 2014: A-line incandescent 100W – 40W
• 2012: 4ft and 8ft T12 fluorescent lamps
U-shaped T12 Fluorescent
Many Par Halogen lamps
Conversion and Maintenance must be planned
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GE Lighting Institute
Industrial Applications and Systems
The Landscape: Financial Incentives
Money is available
• Utility Rebates (vary by Utility)
Examples: T8 Fluorescent Fixture $35.00
Pulse Start 400w replacement: $45.00/fixture
CMH Fixture: $45.00 /fixture
Check with your Utility: Many utilities offer rebates for the purchase and installation
of high-efficiency equipment. Some utilities can also offer financing, tax credits and
planning assistance that can help you during specification and construction.
WWW.CEE1.ORG
• Federal EPACT Tax deductions (extended through Dec. 2013)
Allows the depreciation of a capital asset to be accelerated to one year.
Act Quickly. Incentives are not permanent
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GE Lighting Institute
Industrial Applications and Systems
Financial Incentives: ASHRAE/IESNA
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GE Lighting Institute
Industrial Applications and Systems
Resources to guide you… order on IESNA.ORG
IESNA/NALMCO RP-36-03
ANSI/IESNA RP-7-01
Publications Cover:
Glare and Flicker
Light Sources and Ballasts
High and Low temperature applications
Inspection Lighting
Supplemental Lighting
Emergency , Safety and Security Lighting
Recommended Light Levels
Lumen Depreciation
Lighting Economics
IESNA Industrial Illuminance Levels
Areas include:
Foundries
Farms
Service Garages
Printing Industries
Iron and Steel Industry
Automotive Plants
…and other applications
Task:
Raw material processing
Materials handling
Component manufacturing
Machining
Assembly
Warehousing and storage
Inspection
Service spaces
Shipping and receiving
Maintenance
Motor & equip. observation
Control Panel & VDT observation
Welding
Manual Crafting
FC Range
10 -100
10 - 30
30 - 100
30 - 1000
30 - 1000
5 - 30
30 - 1000
5
30
50
30
10
30 - 1000
30 - 1000
7 /The Lighting Ins
Industrial applications and sy
GE Lighting Institute
Industrial Applications and Systems
ESCO Program
Offering Services & Solutions
Provides end users with information and choices on service options for GE lighting, controls and other
energy optimization upgrades
End User Benefits
•Aligned with qualified, dedicated ESCOs in nation,
regional and local levels specializing in all vertical
markets
•Services including design/build solutions
•Project management, installation and providing
ongoing maintenance services
•Leverage legislative enabling tools to provide rebate
assistance
•Warranty enhancements and simplification
www.gelighting.com/esco
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GE Lighting Institute
Industrial Applications and Systems
Industrial Lighting
Low Bay (Many options available)
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Typically used 14 – 25 ft.
Light Manufacturing, Assembly
Typically used: low watt MH and open strip fluorescent
Issues: Direct glare, uniformity , shadows
Retrofit Options: CFL, CMH and Linear Fluorescent
High Bay (Requires more considerations)
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25 – 50 ft.
Heavy Manufacturing
Typically has: 400W MH Probe Start
Issues: low light levels, heat, dirt
Retrofit Options: Pulse Start MH, T8 and T5 Fluorescent
High Bay is the Largest Retrofit Opportunity
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GE Lighting Institute
Industrial Applications and Systems
High Bay Lamp and Ballast Upgrades
(Lower Watts & More Light)
Old:
250W – 400W Probe Start Metal Halide
on CWA Ballast
To
New: Pulse Start Metal Halide on Electronic Ballast
Ceramic Metal Halide on Electronic Ballast
T8 Fluorescent Lamps
T5/HO Fluorescent Lamps
Plus
Controls: Manual; Motion; Dimming; Energy Mgm’t
Here’s why:
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GE Lighting Institute
Industrial Applications and Systems
The Industrial Hi Bay Issue
Lumen maintenance translates into performance
MVR400/U probe start
lumen maintenance is
40% at end of life
% Initial Lumens
100
90
80
70
60
50
40
30
0
Fluorescent T8 and T5
lumen maintenance is
above 90% throughout life
2
4
6
8
10 12 14 16
Hours Of Operation (000)
18
20
Simple MVR360WM lamp retrofit
saves $200* in energy cost over life
* Lamp plus ballast watts @ 10 cents / kWh for 20,000 hrs.when compared to MVR400/U probe start
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GE Lighting Institute
Industrial Applications and Systems
The Industrial Hi Bay Solutions
Hi Bay System Lumen Maintenance
45000
40000
Lumens
35000
30000
6 F32T8HL
25000
CMH250 eHID
20000
4 F54T5HO
15000
MVR400/U
10000
5000
0
0 12 3
2 34 5
4 56 7
6 78 9
8 10
9 11
10 11
12 13
16 17
18 19
20
1
12 13
14 14
15 15
16 17
18 19
20 21
Hours (000)
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GE Lighting Institute
Industrial Applications and Systems
HID Retrofit Opportunities
Good
Better
Original
Probe Start
Ballast
Pulse Start
Ballast
Retrofit Kit
MVR400/U Std. to
MVR360WM
Saves 40 watts
Best
MVR400/U Std. to
Pulse Start Ballast
With MVR320PA
MVR400/U Std. to
Saves 80+ watts
Saves 150+ watts
With CMH250PA
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GE Lighting Institute
Industrial Applications and Systems
High Bay Retrofit Options
Replace This
MVR400/U Probe Start
M Lumens =
23,500
Watts =
460
LPW =
51
Life =
20,000
CRI =
65
Fixture CU =
60-75%
With These
T5
CMH250 on UltraMax™
M Lumens:
21,275
Watts:
276
LPW:
77
Life:
20K
CRI:
90+
Fixture CU:
.8 - .9
Great in hot/dirty industrials
Great CRI
Good retrofit option
6F32T8HL on UltraMax™
M Lumens:
20,638
Watts:
218
LPW:
94
Life:
25K-36K
CRI:
80+
Fixture CU:
.8 - .9
Excels in open areas
Great CRI
Great retrofit option
4F54T5WM on UltraStart™
M Lumens:
18,400
Watts:
210
LPW:
85
Life:
36K
CRI:
80+
Fixture CU:
.9+
Excels in open or aisles
Great CRI
Great retrofit option
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GE Lighting Institute
Industrial Applications and Systems
GE UltraStart® Watt Miser® Plus T5
System
Standard 4
lamp 54W T5
UltraStart ®
Watt-Miser®
T5 WATT-MISER®
Initial
Lumens = 20,000
Watts
= 234W
LPW
= 85
Initial
Lumens = 20,000
Watts
= 210W
LPW
= 95
Lamp and Ballast
Savings = $72/fixture
UltraStart ® WattMiser® Plus
NEW UltraStart®
Design w/ Lowest
Energy T5 Lamp
Initial
Lumens = 19,200
Watts
= 198W
LPW
= 97
Lamp and Ballast
Savings = $108/fixture
$108/Fixture Saving w/ 4% Less Lumens
Assumptions:
$.10 kwh, 30,000 hrs burn, Savings per 4 lamp 54W T5 fixture
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GE Lighting Institute
Industrial Applications and Systems
Why Lighting is a Good Source for Demand
Response?
• Demand response events usually
coincide with time of day where there
is plenty of daylight
• Lighting provides year-round demand
reduction
• Reducing lighting loads reduces the
burden on HVAC cooling loads
• Lighting does not have a energy
consumption “rebound” effect like
HVAC
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GE Lighting Institute
Industrial Applications and Systems
UltraMax® Dimming Ballast Family
3 families of dimming ballasts
• Bi-Level switching
- built in High BF and Low BF in one ballast
(select 100% or 60% level)
• Load Shed continuous 0-10V dimming control
- dims from 100% down to 60% in continuous control
• Full 100% down to 3% dimming
- uses 0-10V continuous dimming control
 MultiVolt 120-277V
 High Efficiency NEMA Premium
 UL Rating 55C Ambient Approved
 Anti-Striation Control
 UL Type CC Anti-Arc Rating
 -20F Cold Starting Temperature
 RoHS Compliant
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GE Lighting Institute
Industrial Applications and Systems
Line Level Switching… using control devices
S60 Application #1 – High Low Sensor Switching
BLACK Line
BLUE
WHITE
Line
BALLAST
GRAY Line Switching
BLUE
RED
• Simple to use with
occupancy sensors
or Black/White
LAMP
Motion = 100% Light/Watts
Vacant = 60% Light/Watts
Power Off
= 0% Light/Watts
*Switch many fixtures with one occupancy sensor
• Reduce demand w/o
sophisticated controls
LAMP
S60 Application #2 – Using Two Switches
BLACK Line
Line 1
BLUE
WHITE
Neutral
Line 2
BALLAST
BLUE
RED
GRAY Line Switching
• Parallel lamp operation
for fewer lamp
replacements
or Black/White
Switch 1 On/2 Off = 60% Light/Watts
Switch 1 On/2 On = 100% Light/Watts
Switch 2 On/1 Off = 60% Light/Watts
Switch 1 & 2 Off = 0% Light/Watts
*6H - Switch 2 On/1 Off = 0% Light/Watts
LAMP
LAMP
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GE Lighting Institute
Industrial Applications and Systems
Now Here! Controllable Lighting Solutions
What it is: Interactive micro site extension to gelighting.com, focused on GE’s line-up
of energy management ballasts, with application examples and product features.
Goals:
(1) Demonstrate EM strategies
(2) Highlight energy saving
products
- UltraStart® 0-10V
- UltraMax® Load Shed –
- UltraMax® Bi-Level
Dimming
(3) Dollarize an application
example
www.gelighting.com/ballasts
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GE Lighting Institute
Industrial Applications and Systems
Site Components: Energy Savings
How it works: View an example of how to allocate your dimming throughout a 24hour cycle, and the impact vs. fixed light output. Interested viewers come through
as sales leads
Use the “savings” button to
show ‘dollarized’ energy
savings using the technologies
in each application
-
www.gelighting.com/ballasts
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GE Lighting Institute
Industrial Applications and Systems
Hi Bay system selection best practices
• Determine the application needs based on what makes
the business successful… preserve the quality of light
• Evaluate specific conditions that may impact performance
- Dirty, temperature concerns, space characteristics
• Consult with OEM on above for fixture requirements
• Specify GE lamps and ballasts that provide the best
system performance
• Determine how controls can further impact performance
and energy savings
Don’t forget to assess your Outdoor Area Lighting
for the latest upgrades and quality improvements
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GE Lighting Institute
Industrial Applications and Systems
Trends in outdoor safety and security lighting
GE Evolve™ LED Area
GE Evolve™ Contemporary
LED Area
GE Evolve™ LED
Cobrahead
• Lighting regulations and standards are becoming more aggressive
to meet energy codes, legislation and environmental concerns
• HPS is being replaced by white light Metal Halide or LED where
people safety is a concern (we see better under white light)
• LED area fixtures deliver equal or more light than HID…
but at < half the wattage and with better uniformity
• LED bluer white light is perceived to be brighter than other sources
• New B.U.G. lighting Luminaire Classification System is being used
to improve on light trespass, light pollution and glare issues
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GE Lighting Institute
Industrial Applications and Systems
But I’ll bet you have lots of questions????
What are my Light Levels?
How much will I save?
How much does all this cost?
How many fixtures do I need?
What is the payback? ROI? Cash Flow?
Warranties?
Lamp Life ?
Ballast Life?
We have the resources to answer your questions
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GE Lighting Institute
Industrial Applications and Systems
We have a lot of ways to get you’re the correct answer
User friendly tools
Plus
ValueLight™ Analysis
Facility Audits
Testimonials
Environmental guidance
… and much more
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GE Lighting Institute
Industrial Applications and Systems
The Next Step to Savings:
Based on what you learned today – do you
want a GE representative to contact you for
a FREE facility audit?
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GE Lighting Institute
Industrial Applications and Systems
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GE Lighting Institute
Industrial Applications and Systems