LED Technology & Customer Value LEDHEAD

2014 Eaton. All Rights Reserved..
LED Lighting For Harsh & Hazardous Locations

Eatons Crouse-Hinds Business
LED Lighting Technology & Customer Value

2
Agenda
Eatons 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
Company Overview
Syracuse, NY Headquarters and one
of 35 global facilities today
Preferred Solution for Engineering Safety & Productivity for 115 Years
Worlds 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
For Oil and Gas, we are the global electrical leader in
upstream, midstream, and downstream environments
5
Our Product Lines Deliver Safety and
Reliability When It Matters Most
Explosive vapors and dusts
Moisture Extreme Temperatures Corrosion
LED Technology Vs Traditional Lighting
7
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
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
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
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
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
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
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
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
LED Technology Projection (DOE 2012
LED Efficiency improvements
are outpacing projections
and expectations for the
foreseeable future
Myths & Misconceptions LED Lighting
17
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
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
L
i
f
e

(
H
o
u
r
s

K
)

Fixture Life (Econ. Vs. Rated)
Economic
Life
Rated Life
60,000
172,000
19

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 fixtures ability to effectively illuminate
a targeted area NOT raw lumens
Directional nature of LEDs makes them suitable for use with custom optics
20
Third Party Performance Testing &
Validation - LM79 Report
Defines how to measure photometry
and chromaticity for LED lamps and
fixtures
Fixture measured at 25C 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
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 LEDs 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

Benefits & Enabling Design Features
Environmental, Operational & Safety
23
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
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 $$
Utility Rebate
Material Reduction Costs **
One Time Tax Savings
** Circuit Size, wiring, panel boards
Operational Benefits
25
SAFETY
Beyond Economic
Impact $$
Maintenance
Free
Operation
Lower
Temperature
Codes
Vibration,
Corrosion,
Dust & Water
Resistance
Lighting
Quality
Electrical
Protection &
Reliability
Installation
Safety Benefits

26
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
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
L
i
f
e

(
H
o
u
r
s

O
f

O
p
e
r
a
t
i
o
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
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
40C T4 T70
55C T4 T85
40C T5 T60
55C 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
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
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
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
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
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/m is
not permissible and is hazardous
= physiological glare
34
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
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
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
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
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
Application Examples & Installations
40
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
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
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
Summary
44
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
Industry-leading, Global LED Portfolio
Eatons 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

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LED Technology & Customer Value LEDHEAD