led lighting · 2020-04-12 · lighting is omnidirectional led is directional with focused lighting...

© 2012 Eaton Corporation. All rights reserved. Confidential

LED Lighting WMEA Conference

November 22, 2013


What Does LED Stand For Light

Emitting

Diode


LED vs. Traditional Lighting Overview

5 © 2013 Eaton, All Rights Reserved. Confidential

• 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 mining environments

Key Issues

• Safety

• Maintenance expenses

• Rising energy prices

• Lifecycle costs

• Environmental pollution

• Harsh environments

Lighting Facts


LED Compared To Traditional Sources

• No filaments like incandescent lamps

• No electrodes like gas discharge lamps (HPS, MH, and fluorescent)

• Devices are robust, vibration & impact proof; very rugged and

durable

• Instant on, full color, 100% light; cold start capable

• No mercury in the light source

• Long life – reduced maintenance costs


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

8 © 2013 Eaton, All Rights Reserved.

Newmont Carlin – Elko, NV



Control Panel for Stacker


LED Environmental, Operational and Safety

Design Features


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


Rio Tinto Kennecott Copper - Salt Lake City, UT

Kennecott Smelter

Tank Area


Kennecott Area Lighting

& Smelter



• 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


Colowyo Mine – Dragline Boom Lighting


Safety Benefits


Safety Benefit Maintenance-Free

The best way to prevent a maintenance

accident is to minimize the need for it

Maintenance-Free Operation

• LED fixtures offer longer

life vs. conventional light

sources

• LED technology alone is

not enough to drive long

life

• Key drivers to long life

include Driver life, LED

component selection,

thermal management, T-

codes and robust

design


• 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


Robinson Copper - Ely, NV

Application: Shovel Lighting


PVM9L 90° Stanchion on

cooling tower & landings



Newmont Leeville –Elko, NV

Application: Conveyor Stacker



Application: Filter Press


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


Dust Marine Hose Vibration up to 3G

& 5G forces

Safety Benefit Reliability in Adverse Conditions

Fixtures Designed To Withstand The Harshest Conditions

champ-vmv-led-dust-test.mp4

champ-vmv-led-hose-test.mp4

pfm25l-floodlight-highvibration.mp4


Safety & MSHA

SAFETY Beyond Economic

Impact $$

Maintenance Free

Operation

Lower Temperature

Codes

Vibration, Corrosion,

Dust & Water Resistance

Lighting Quality

Electrical Protection &

Reliability

Installation


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

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

• Binning

• LED component selection


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


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

Electrical Protection: Drivers



Application: Roadway Relighting Project


Roadway Lighting



Newmont Leeville – Elko, NV

Application: Bus Stop Lighting


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 foot candles

• 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

led lighting · 2020-04-12 · lighting is omnidirectional led is directional with focused lighting...

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