DESIGN OF LED BASED MODULAR INDUSTRIAL HIGH BAY LUMINAIRE

Varun Vijayan
Manipal Institute of Technology Manipal, India varunv88@gmail.com

Savitha G Kini
Manipal Institute of Technology Manipal, India savithakini@yahoo.com

Amrith Prabhu
Philips Lumileds Lighting Company Bangalore, India amrith.prabhu@philips.com

M V Roy
Philips Lumileds Lighting Company Bangalore, India mv.roy@philips.com

Abstract In India, most of the industrial spaces use conventional fluorescent systems or high intensity discharge (HID) lamps like high pressure sodium vapour (HPSV) and metal halide (MH) as light sources for general illumination. They are less energy efficient and are prone to frequent relamping due to aging. This paper discuses the design of a luminaire with more efficient, environment friendly and more reliable Light Emitting Diode (LED) sources. A unique modular design is used for the luminaire which makes it scalable and more optically controllable. The focus is on the design of a LED high bay luminaire as a one to one replacement for a 250W MH luminaire that can increase sustainability, productivity and functionality of the industrial space. The intent is also to evaluate the possible energy saving potential in comparison to the conventional metal halide luminaires. The developed luminaire had an overall luminous efficacy of 93 lumen per watt which is very much superior to 50 lumen per watt conventional MH luminaire. In addition, the LED prototype consumed 51 percent less energy in comparison with the MH luminaire. Index TermsSolid state lighting, energy conservation, industrial lighting, high bay, luminous efficacy

height is more than 7.6m and Low-Bay luminaires where the mounting height is less than 7.6m (Illuminating Engineering Society of North America (IESNA) RP-7-01, 2001). At present for general lighting in industry, two basic types of lighting solutions are dominantly found. Lighting solutions based on linear light sources and point sources. Linear sources typically include fluorescent lamps and point source solutions with highintensity discharge lamps (HID) like high pressure sodium vapour (HPSV), metal halide (MH), and high pressure mercury vapour (HPMV) lamps. Conventional lamps have low system efficacy and need frequent lamp replacement because of their less lifetime. By using solid state lighting technology, there is a great potential to minimize energy consumption and to increase the quality of light in the industrial environments. Since an actual LED bulbs lifetime is much longer than fluorescent and HID lamps, it not only saves the cost of replacement, it will also save the labour costs to continuously replace failing bulbs as well. Replacement of bulbs which tends to be more expensive in industrial spaces due to mounting height and difficulty in accessing the lighting can be taken care of by properly designed LED luminaires. II. METHODOLOGY The goal of the design is that the LED luminaire that can replace a 250W MH luminaire in high bay applications. Philips make Optibay HPK225 luminaire is selected as it is widely used in industry. Fig. 1 shows the luminaire.

I. INTRODUCTION Lighting accounts for 15-20 percentage of total energy consumption in a developing country against 7-10 percentage in developed countries (International Energy Agency (IEA), 2008). The sole reason for this higher energy consumption is the use of inefficient light sources. Thus the need of an alternate technology towards energy efficient lighting solution is high. Light emitting diode (LED) lighting, an emerging segment in world lighting market and specifically in India, is driven by this need has gained importance in last few years. Industrial lighting covers a wide range of working interiors and variety of tasks. Their typical applications include warehouses, production facilities, manufacturing and assembly lines. Electricity drives all the industrial spaces and since most of them are energy intensive, there is a primary push for power savings. Lighting is one such area which is focused upon because of its use throughout the day and night. Industrial luminaires are generally divided into two categories HighBay and Low-Bay. High-Bay luminaires are designed to produce general illumination in the space where the mounting

Fig. 1 250W Philips Optibay HPK225 MH high bay luminaire

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in requirement for luminous flux can be dealt with increasing or decreasing the number of modules. Fig. 3 shows the proposed design. B. Selection of LED The selection of LED is based on the required lumen density, the form factor of the luminaire and the luminous efficacy requirement. The numbers of LEDs required are calculated based on the thermal and optical efficiencies considered.Two LEDs from Philips Lumileds were considered, namely Luxeon M (DS103, 2013) and Luxeon Rebel ES (DS61, 2011). The former one is 2W emitter and the latter an 8 W (both @700mA). Table 2 cites the comparison between the two emitters considered.
Table 1 Luminaire Specification Characteristic Fig. 2 Block diagram of the LED lighting system Light Output Power Luminaire Efficacy Lifetime CCT CRI Power Factor Beam Angle Unit Lm W lm / W Hours K 100-point scale Degrees Target Goal 12000 <150 85 35000 5000 >75 >0.85 60

The Philips HPK225 250 MH luminaire has a lumen output of 13,675 and system wattage of 274W. The overall luminous efficacy of the MH luminaire is 50 lm/W and has an average life of 20,000 hours. Any LED system has four functional units; the LED, Optics, Driver and Thermal management. Fig. 2 shows the complete block diagram of a typical LED system. The frame work basically involves designing each of the functional blocks. A. Framing the Design Specifications Based on the detailed survey of conventional industrial lighting solutions, the specification for the LED luminaire was laid out. Along with the luminaire design requirements, the lighting requirements were also fixed for a specific industrial space. Steel fabrication industry was considered for the simulation purpose. LED being a directional light source, the same performance can be obtained using a lower luminous flux in comparison to the conventional light sources which are omni directional in nature. To fix the light output required from the LED luminaire, preliminary dialux simulations were carried out for a sample area. From this result, light output required was set at 12,000 lumens. Other parameters for the luminaire like beam angle, CCT and CRI were fixed after multiple simulations in dialux and based on the most commonly observed values. Lux level requirement was finalized at 300lx from the Indian standard code for practice for interior illumination (Indian Standards (IS) 3646 Part I, 1992). Table 1 shows the design requirements. For the dialux simulation, workplane is set at 0.85m and the uniformity to be maintained is set at 0.5. A unique cost effective modular design solution is proposed for this high bay luminaire. Whole luminaire consists of four easily attachable modules and independent thermal management solution for each of them. This makes maintenance of the luminaire hassle free and scalable. Change

Fig. 3 Modular design of the luminaire Table 2 Comparison of LEDs considered Parameters Typical Vf (V) Max If (mA) Drive Current (mA) Test Temperature (C) Hot Cold Factor @ 85 C Flux Bin Lumen Output (lm) CCT (K) CRI Luxeon Rebel ES 3 1000 700 25 0.88 X 280 5650 70 Luxeon M 11.2 1050 700 85 1 S 900 5700 70

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For a target lumen of 12,000 lumens, no of LEDs required is calculated using lumen output from each LED, lens efficiency and Hot Cold Factor (HCF). Lens efficiency was considered 85 percent which is more or less a typical value. HCF for Luxeon M and Rebel ES are 1 and 0.88 respectively. (1) From equation (1), numbers of LEDs required are 55 (for Luxeon Rebel ES application) and 15 (for Luxeon M application). In order to arrange symmetrically in four modules, the number of LEDs are modified as 56 and 16 respectively. Since each module is supposed to be compact and small, fitting in 14 Luxeon Rebel ES is difficult and can affect thermal management. Also more number of lenses means more no of components, less reliability, more cost. On the contrary Luxeon M, due to high flux density enables just 4 of them enough for a module to meet the target specification. Thus Luxeon M is selected as the best option available for this application. C. Selection of Optics The secondary optics for the LEDs must be selected so as to replicate the Light Distribution Curve (LDC) of conventional luminaire which is in consideration for replacement. The beam angle distribution required is thus a narrow beam. Different make lenses with various beam angles were considered for Dialux simulations. The lens which matches best with the lighting requirements and LDC was selected. B & M optics AC107-L606T array lens was chosen which can be mounted on 4 Luxeon M LED modules. Figure 6 shows the lens. It is made up of optical grade poly carbonate and has very good UV resistance. The lens has an exit beam angle of 60 degrees and transmittance (lens efficiency) of 88 percentage. Fig. 4 and Fig. 5 show the light distribution curve of the lens and Philips HPK225 luminaire respectively.

Fig. 5 Light distribution curve of Philips HPK225

D. Selection of Thermal Management Solution Thermal management system required depends on the total wattage of LEDs that are mounted on top. For each module individual thermal solution is formed and four LEDs are mounted on each of them.Circular aluminium extrusion heat sink profile was selected which has radial fins. To achieve minimum lumen depreciation and to ensure best performance, the junction temperature has to be maintained within 100C. Usable Light Tool (ULT) was used to simulate and finalize the size of the heat sink. The heat sink has a diameter of 16cm and height of 5cm. The calculated junction temperature and thermal resistance is 87C and 0.65C/W respectively. Fig. 6 and Fig. 7 show the ULT simuation graphs. Fig. 8 shows the profile of the selected heat sink selected.

Fig. 6 Usable Efficacy vs. Heat Sink Rth Fig. 4 Light distribution curve of B &M AC107-L606T

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F. Prototype Build For the modular design solution adopted, four modules are connected to a central shaft to form the complete luminaire. Four Luxeon M LEDs are reflow soldered into each Metal Clad Printed Circuit Board (MCPCB) and along with the lens, they are attached to heat sinks. These heat sinks are then bolted to the clamps to form individual modules. Fig. 9 shows the MCPCB and heat sink. These four individual modules are then attached to the central extruded aluminium pipe. A threaded iron rod is inserted to the shaft and bolted from both sides using two threaded iron discs. The four modules are connected in series and the lead wires are drawn out from the top disc. The LED driver is then connected to these wires to power the LED modules. Fig. 10 and 11 shows the assembled luminaire.
Fig. 7 Actual Tj vs. Heat Sink Rth

Fig. 9 6cm X 6cm MCPCB and the modified heat sink

Fig. 8 Heat sink profile

With this heat sink, the calculated junction temperature at 700 mA driving current is 87C and calculated usable flux from single LED is 896 lumen (900 lumen @ 85C). The usable efficiency of a single LED is calculated as 114 lumen per watt. Moreover, it is black anodised to improve the heat radiating capabilities. E. Selection of Driver All 16 Luxeon M LEDs are connected in series. Each LED has forward voltage of 11.2 V and driven at 700 mA. The total string voltage is 179.2 V and thus power required to drive the system is 125.44W. Market ready constant current driver which matches with the required current and voltage is used. Nearest available standard power rating is 150 W. Philips Xitanium driver was selected as it meets the specifications. Table 6 shows the driver specifications.
Table 3 150W Xitanium driver specifications Parameters Efficiency (%) Output Power (W) Power factor Output Current (mA) Output Voltage (V) Value 92 42-150 0.98 700 60-210 Fig. 11 Bottom view of the luminaire

Fig. 10 Fully assembled luminaire

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III. PROTOTYPE TESTING Testing is done in two parts. A thermal measurement test using thermocouple to measure the junction temperature of the LED and a photometric testing to analyze the lumen output, luminous efficacy and light distribution curve. A. Thermal Measurement The typical thermal resistance Rth(j-thermal pad) between the junction and thermal pad for LUXEON M is 1.25K/W. With this information, the junction temperature Tj can be easily determined according to the following equation
(2) Fig. 13 Relative light output vs. junction temperature

In equation (2), Tthermal pad is the temperature at the bottom of the Luxeon M thermal pad and Pelectrical is the electrical power going into the Luxeon M emitter. In typical applications it may be difficult, though, to measure the thermal pad temperature Tthermal pad directly. Therefore, a practical way to determine the Luxeon M junction temperature is by measuring the temperature Ts of a predetermined sensor pad on the Printed Circuit Board (PCB) right next to the Luxeon M emitter with a thermocouple. The recommended location of the sensor pad is 0.5mm from the edge of the Luxeon M emitter, on the center line between anode and cathode as shown in Fig 12. The thermocouple must make direct contact with the copper of the PCB onto which the Luxeon M thermal pad is soldered, i.e. any solder mask must be first removed before mounting the thermocouple onto the PCB (AB103, 2011). The thermal resistance Rth(j-s) between the sensor pad and the Luxeon M junction was experimentally determined to be approximately 3.0K/W on a MCPCB (DS103, 2013). The junction temperature can then be calculated as follows.
(3)

Since the change in temperature is the same throughout, the result is extrapolated to find out the junction temperature at a real time ambient temperature of 40C ambient which is 91C. Luxeon M LED is hot tested at 85 C and the HCF is 0.985 which can be obtained from Fig. 13.The luminous flux from a single luxeon emitter whose Tj maintained at 85C driven at 700 mA is 900 lumens. When HCF is considered, the effective lumen output is reduced to 886.5 lumens. B. Photometric Testing Lighting systems can be measured using two different methods of photometry, absolute or relative. Relative photometry is commonly used with conventional lighting products and allows for the combination of separate measurements for a lamp and luminaire. In contrast, the performance of LED lighting system has a dependency on its components reliability. This necessitates measurement using absolute photometry, which considers the complete product. Manual gonio photometer was used and the photoreceptor was placed at 6m from the optical centre. At an interval of 5 degrees the lux readings were taken for four vertical angles. These readings were then used to calculate the luminous intensity distribution, total luminous flux and the exit beam angle of the luiminaire. Fig. 14 shows the light distribution curve of the prototype and Table 4 details the performance parameters as obtained from testing.

The sensor pad temperature (Ts) is measured using a thermocouple and was 52 C and the power drop (Pelectrical) across one Luxeon M emitter driven at 700 mA is 8W. This measurement was done at 25C ambient temperature at which the junction temperature was 76C.

Fig. 12 The recommended temperature measurement point Ts Fig. 14 LDC Polar

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Table 4 LED prototype photometric test results summary Parameters Lamp Lumens (lm) Luminaire Lumens (lm) LED Wattage (W) System Wattage (W) Luminaire Efficacy (lm/W) Value 14,400 12,672 128 136 93.3 Work plane Surface

Table 5 Dialux simulation comparison Reflectance (%) / 250W MH Design Eav U0 (lux) 320 0.532 128W LED Design Eav U0 (lux) 317 0.504

C. Dialux Simulations Dialux is one of the widely used lighting simulation software for exterior as well as interior environments. Real time conditions can be incorporated into the simulation to have a close look on the performance before installation of luminaires in a space. Simulations are carried out for the industrial space with conventional and LED luminaires to compare and analyze the energy savings and performance parameters. The size of room considered is 30m x 20m x 12m and the work plane is set at 0.85 m from floor level. Light Loss Factor (LLF) for LEDs is considered to be 0.9 because of their very less lamp lumen depreciation in comparison with conventional light sources. Fig. 15 and Fig. 16 shows the dialux POV ray tracer view of the room simulated.

A total of 20 luminaires are used in both the simulations where 5 along the length and 4 along the width. The dialux simulations in Table 5 show that the LED prototype luminaire meets the requirements of maintaining 300 lux and a uniformity of 0.5. Thus the finished LED luminaire can be used for one to one replacement of a 250 W MH luminaire. IV. RESULT ANALYSIS Two tests were done to evaluate the performance of the prototype luminaire. A thermal measurement to measure the junction temperature of LED and thereby quantify the thermal management solution designed for the luminaire and then a photometric test to measure the luminaire lumens, luminaire light distribution, system efficacy, CCT and other relevant performance characteristics. The junction temperature at a set 25 degree ambient temperature was 76 C. The extrapolated junction temperature at a real world application where the ambient temperature can be about 40 C is 91 C. The luxeon M LED is hot tested at 85 C and the datasheet values correspond to the same test temperature. The reduction in light output of an LED by the influence of rising junction temperature is denoted by a factor called Hot and Cold Factor (HCF). For this application, HCF is 0.985 and it denotes that with this designed thermal management solution, the reduction in light output is just 1.5% from the datasheet reference values. The designed thermal management solution is thus very much optimized and capable enough to maintain Tj within limits. The lumen maintenance for LEDs are expressed in terms of percentage of initial light output remaining after a specified burning hours. On average 70 % lumen maintenance (L70) is achieved at 50,000 hours if the forward current is up to 700mA and junction temperature maintained on or below 135 C. Since this conditions are satisfied in this application, this projected lumen maintenance is achievable. The photometric results show that the light distribution curve is similar to the conventional luminaires and the system luminous efficacy is about 93 lumens per watt which is far superior to the conventional lighting systems. A comparison is drawn using the dialux simulation using two technologies i.e. LED and MH sources. This gives a performance comparison in terms of power consumption, luminous efficacy, lux level maintained and uniformity achieved.

Fig. 15 Room simulation 250W MH

Fig. 16 Room simulation 128W LED

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V. CONCLUSIONS In any country, the economical development has its direct dependence on the growth of industries and efficient industrial lighting is one important area which must be given due importance. It is the reason why LEDs emerge as the technology of choice in industrial lighting. LEDs outstanding energy efficiency (40 to 60 percent more than conventional lighting technologies), lesser maintenance costs, and eco friendliness have popularized them among outdoor and indoor lighting applications. In most of the industrial spaces, where the lighting is on for almost whole of the day because of the manufacturing or assembly line, energy saving by 40-60 percent can make a huge saving in terms of the electricity bill. Another important factor to be considered is the relamping and maintenance of the luminaires. This also adds to additional labour cost and generally lighting maintenance is a difficult task because of their mounting heights (especially in high bay area). LED luminaire because of the long life and reliability can save this extra cost in comparison to the conventional luminaires. The instant on performance of the LEDs added with the superior colour rendering quality enhances their benefits. The modular design of the luminaire makes it very much scalable. Up to 51 percent savings in terms of energy is achieved due to this switching.

REFERENCES
Neary, M., Quijano, M., Solid state lighting for industrial locations, Petroleum and Chemical Industry Conference, 2009. PCIC 2009. 2009 Record of Conference Papers - Industry Applications Society 56th Annual Conference, pages 1-7 Cheng, Y.K., General Study for using LED to replace traditional lighting devices, Power Electronics Systems and Applications, 2006. ICPESA '06. 2nd International Conference on, pages 173 177 Standard practice sub-committee of IESNA, ANSI/IESNA RP-7-01 Recommended Practice for Lighting Industrial Facilities, IESNA 2001 Illumination Engineering and Luminaires Sectional Committee - BIS, National Lighting Code 2010, BIS 2010 Illumination Engineering and Luminaires Sectional Committee - BIS, IS 6665-1972 Indian Standard Code of Practice for Industrial Lighting, 1972 Philips Lumileds, Luxeon M Assembly and Handling Information, Application Brief AB103, 2011. Philips Lumileds, Luxeon M , Datasheet DS103, 2013 Illumination Engineering and Luminaires Sectional Committee ETDC45 , Indian Standard Code of Practice for Interior Illumination 3646 Part I, 1992

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