You won't just be saving on energy costs when you install LED lighting - maintenance plays a big part in the savings too

1. Cutting Energy & Maintenance Costs
with LED Lighting
… and at the same time improving light quality
and reliability

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DialightSo what is an LED?
Solid-state semiconductor technology
- Smallest light source available
- Mercury & lead free material (RoHS)
- Silicone lens
- Die
- LED package
- Solder pad
LEDS are the most efficient white
light source
Solid state semiconductor
technology with no air, glass or
fragile filaments - they're the
most robust and efficient light
source
The die emits blue light and is coated with phosphor that
absorbs a portion of the blue light and re-emits it as other
colours to fill in the spectrum resulting in white light.

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DialightLED Technology – old vs new
c 20,000 hrs lifetime v >100,000 hrs

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DialightTypical white LED roadmap
Add 20-30% over next 5 years

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
High Pressure Sodium
The industry has recognised HPS as a standard due to its high efficacy and lumen maintenance,
but the largest issue with it is the colour it emits, which appears to the human eye as orange
and represents poor quality of light at night. This presents a significant risk in hazardous
environments at night, since machine operators and maintenance workers need to quickly and
easily identify coloured wires, safety plaques, liquids, objects or smoke.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
Low Pressure Sodium
LPS is technically not a white light source but has been used in lighting. LPS has very high
bulb efficacy (up to 200 lumens/watt) but has the worst colour quality.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
Mercury Vapour
Mercury vapour is fairly inefficient with a bulb efficacy of about 50 lumens/watt (when
phosphor coated) and has a poor CRI of up to about 50. The phosphor coating on the glass
of the bulb makes it a large source size and therefore difficult to control the light
distribution precisely. For these reasons, and due to the use of mercury, these lamps are
not commonly used any more.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
Metal halide
Metal halide is a common light source used today because of its good colour quality (85-95)
and low cost. Metal halide suffers from rapid lumen depreciation and the lamps contain
mercury.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
Fluorescent
Fluorescent fittings are common light sources used today due to their high efficacy (55-100
lumens/watt) and good colour rendering (50-90). While they have good lumen
maintenance they fail catastrophically at end of life and contain mercury. The source size is
large because of the use of phosphors and therefore controlling the light distribution is
difficult and can result in poor utilisation of light.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
CFL – Compact Fluorescent
Compact fluorescent (CFL) lamps have good CRIs (50-90) but mediocre efficacies (50-75
lumens/watt) and they contain mercury. The source size is large due to the use of
phosphors and therefore controlling the light distribution is difficult and can result in poor
utilisation of light.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
Incandescent
Incandescent lamps have the highest CRI (up to 100) but the lowest efficacies (5-25). Their
fragility is also an issue for industrial applications.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
Induction
Induction lighting is similar to fluorescent but is an electrode-less light source and therefore
has long life (over 100,000 hours). It has good CRI (50-90) and good efficacy (60-90 lumens
per watt). The source size is large due to the use of phosphors and therefore controlling the
light distribution is difficult and can result in poor utilisation of light.

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 150 100+
LEP – Light emitting plasma
Light emitting plasma is the newest light source technology. Being an electrode-less light
source it has long life (over 100,000 hours). It also has good CRI (50-90) and good efficacy
(60-90 lumens per watt).

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DialightLED vs other lighting technologies
Light source CRI Lumens/watt
Lifetime in hours
(x1000)
High pressure sodium 30 60-120 10-24
Low pressure sodium 5 200 10-24
Mercury vapour 50 50 10
Metal halide 70-95 60-100 6-20
Fluorescent 60-90 40-100 6-45
CFL 60-90 50-75 6-15
Incandescent 90-100 5-25 1
Induction 50-90 60-90 100
LEP 50-90 60-90 100
LED 70-90 Up to 160 100+
LED
LEDs are “full-spectrum” light sources with no gaps in the colour spectrum. They have good
CRI (70-85) and the highest efficacy (up to 160 lumens/watt) of the white light sources.
LEDs emit light in a hemispherical direction instead of a full spherical direction. Because the
light is only directed forward, the optics can be simpler and are more efficient. LEDs are
highly robust and can last well over 100,000 hours.

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DialightProblems with existing lighting technologies
Poor quality of light
Large installed base of inefficient high
pressure sodium fittings
Excessive use of energy
Safety & maintenance risks
Sudden & unexpected light failures
Audible noise produced
Unlike LEDs with instant-on ability,
fittings such as HID and fluorescent
do not turn on instantly at full
brightness and therefore are often
left on when not in use.

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DialightTechnology Comparison: HPS
400W HPS Lamp Startup Colour Shift
• Efficiency - 100 lm/W
• Colour quality CRI = < 30
• Lumen maintenance - L70 = 16,000 hours
• Longevity - bulb life = 24,000 hours

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DialightTechnology comparison: HPS
Typical makeup of bulb material
Known Issues
• Susceptible to colour shift at end of life
• Poor T-rating (of concern in hazardous areas)
• Unreliable in extreme temperatures
• Unable to handle extreme shock & vibration
• Can only be dimmed to 50%
• Long re-strike time (up to 15 mins)
• Contains 30mg of mercury (400W bulb)

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DialightTechnology comparison: Metal halide
• Efficiency - 80 lm/W
• Colour quality - CRI = 75
• Lumen maintenance - L70 = 6,000 hours
• Longevity - bulb life = 16,000 hours
• Long startup times
Known Issues

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DialightTechnology Comparison: Metal halide
Typical makeup of bulb materialKnown Issues
• Susceptible to colour shift
• Poor T-rating (hazardous location issue)
• Unreliable in extreme temperatures
• Unable to handle extreme shock & vibration
• Can only be dimmed to 50%
• Long re-strike time (up to 20 mins)
• Contains 38mg of mercury (400W bulb)

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DialightRelative T-ratings of light sources
Maximum
Surface Temp
CENELEC EN 50
014 IEC (Group II)
60079-8 NEC®
505
NEC 500 – Table
500.8 (B)
450°C (842°F) T1 T1
300°C (572°F) T2 T2
280°C (536°F) T2A
260°C (500°F) T2B
230°C (446°F) T2C
215°C (419°F) T2D
200°C (392°F) T3 T3
180°C (356°F) T3A
165°C (329°F) T3B
160°C (320°F) T3C
135°C (275°F) T4 T4
120°C (248°F) T4A
100°C (212°F) T5 T5
85°C (185°F) T6 T6
Metal
Halide
HPS
LED
Temperature Classification

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DialightThe importance of LED fixture design
Thermal Design Electronic Design
• Maximise useable light
• Increase light spacing
• Improve uniformity
• Manage heat from LEDs
• Manage heat loss from
driver
• Minimise conducted
heat reaching driver
• Power LEDs efficiently/drive
current 350MA/500/750 etc
• Implement control features
• Protect against transients in
the electronics
Optical Design

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DialightMaintenance savings
• Maintenance costs up to $2,000 per lamp!
• Traditional lamps often don’t reach full
expected life due to vibration, excessive heat
• Hazardous areas require multiple personnel,
permitting, scaffolding
• Production down time = $$$
How does maintenance savings
affect payback?
Expected life
• Metal halide bulb = 2 years
• LED fixture = 10+ years
Scenario
• $1,000 / year
• (100) 153W LED High Bays replace
• (100) 480W HID High Bays
Annual Savings:
• Maintenance Savings $100,000 / year
• ~1 year payback
Maintenance savings : $100,000 / year
Hazardous location example

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DialightApplication case study: savings with rebate*
Project Overview
• (140) 400W HID vs. (140) 150W LED
• Initial spend: $80,000
• Utility rebate incentive: ($48,000)
• Annual Energy Savings: ($16,000)
• Annual HVAC Savings: ($8,000)
• Annual Maintenance Savings: ($15,000)
• CO2 Reduction: 124 tons
Payback w/ Rebates = < 1 yearBaby Wipe Manufacturing Facility
*US only

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DialightApplication case study: savings on energy alone
Project Overview
(136) 250W and (100) 400W HID vs. (126)
150W LED – lights in use 24/7
HID were actually drawing 280W and 430W
• Annual Energy Savings: (£42,000)
• W/sqm down from 3.85 to 1.05
• CO2 Reduction: 271 tons
Payback = 1.1 yrs on energy
saving alone
Distribution warehouse for logistics company
LED lighting in foreground and HID at back

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DialightApplication case study: savings inc maintenance
Project Overview
(13) 400W HID vs. (8) 172W LED – HID
were actually drawing 440W
Lights in use 8 hrs per day, 5 days a week,
50 weeks a year
• Initial spend: £4320
• Annual Energy Savings: (£695)
• Annual Maintenance Savings: (£2297)
Annual maintenance of shed lighting
involved cost of 2 men for one week + hire
of cherry picker, cost of 13 replacement
polycarbonate lenses and 4-5 lamp
changes. All of this can be eliminated by
using LED high bays which can be expected
to last for 10 years or more.
Payback = 1.3 yrs
Bulk storage shed at port facility
Lamp maintenance only possible when the
shed is empty, so many lights were often out

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DialightLighting controls and monitoring
To further enhance safety, predictability and measurability, LED lighting manufacturers
are introducing light systems that can be monitored remotely. These systems come with
a communication device built into the fixture, integrated with the driver circuitry and the
two communicate with each other. The fixtures transmit data to a central, remotely
located monitoring system and have the ability to report pertinent information related to
the lighting system (lumen output, energy consumption, etc).

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DialightFuture of LED technology – advanced controls
• Faster payback period / further
energy reduction
• Occupancy sensor integration
• Advanced dimming based on user
defined settings
• Controlling individual or groups of
LED fittings to reduce wasted light
• Demand response
• “Smart” lumen depreciation
settings to maintain original light
levels
LED technology allows for the lights to be dimmed with simple circuitry
and paired with occupancy sensors to create a ‘smart’ lighting system.

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DialightFuture of LED technology: Monitoring/reporting
• Real time notifications
• Predictable energy usage
• Custom reporting based on user recs
• Zero maintenance lighting system
• Emergency fitting battery life
monitoring
• Failure detection and notification

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DialightSummary
This is how LED technology compares to other lighting technologies:
- It consumes less power
- It has instant-on ability
- It performs better in extreme conditions
- It lasts longer to reduce maintenance costs
- It contains no mercury or hazardous material
- It generates a better quality of light
- It provides better ROI compared to conventional technologies
- It’s ready for integration into ‘smart’ lighting solutions

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DialightWant to know more?
www.dialight.com
info@dialight.com
TCO calculator – try our
calculator to find out what
you could save by installing
LED lighting.