Conversion Guide: From HID to LED

The wide-range of new LED technology now available offers owners and tenants more choices than ever, but navigating all the options has become increasingly difficult. Download this guide to discover how your time and investment can save you in the long run.

Id 35228 Forever Lp
“Conversion Guide: From HID to LED”. By Foreverlamp, Inc. – The industry leader in high bay LED l ighting solutions Jim Sekinger - 844-533-8811 Commercial warehouse and industrial buildings have an energy problem: HID high bay lights are expensive to operate and provide poor quality light. The wide- range of new LED technology now available offers owners and tenants more choices than ever, but navigating all the options has become increasingly difficult. Nevertheless, these recent product innovations and the advent of Lighting as-a-Service ("LaaS") makes this the time to upgrade your facility. N O M A D I C | 2 4 WHY NOW? Recent innovation in LED technology and dramatic cost reductions of LED chips, has greatly expanded the range of lighting solutions for high bay applications. This includes new thermal management systems and significant improvements in lumen/watt efficiency that allows for higher lumen output light sources. In addition, new up-light designs have improved LED options for many applications, especially retail.  There are two main approaches to warehouse lighting retrofits: lamp replacement (plug-and play or by- pass lamps) and fixture replacement (installing new integrated LED fixtures). Our comparison below explains the benefits and drawbacks of each approach. Improved Technology Plug-and-p lay lamps By-Pass lamps What is it? Using the existing magnetic ballast,  simply screw out the old lamp and screw in the new LED.  Typically saves 50% on of the lamp energy (e.g. 400W to 200W) Pro’s - Highly sustainable – re-uses entire existing fixture - More lumens for high mounting heights - Does not require a licensed electrician for install - Works with any input voltage Con’s - If ballast goes bad it must be replaced What is it? An electrician cuts the power from the ballast to the socket then re-wires the socket to incoming line voltage. Screw out the old HID lamp and replace it with the voltage specific lamp.  For ballast bypass retrofits, where the wiring is disconnected from the ballast and directly connected to the bulb socket, a fast acting fuse should also be installed to prevent explosions in case a conventional metal halide is later installed without reconnecting the ballast. This is a safety precaution that will add to the overall cost of the project. Typically saves 50% on of the lamp energy (e.g. 400W to 200W) Pro’s - Cost effective when existing ballasts are bad - Good solution for low mounting heights (20’ or less) Con’s - Low lumen output - Requires licensed electrician to install - Left with line voltage on socket New LED  f ix tures New LED fixtures are available in a wide range of designs from the inexpensive UFO style to a high performance, classic high bay. To help make the best decision for you and your facility start with these five steps: 1) Establish a budget. As you might expect there are many price points in the LED market. Low quality, inexpensive fixtures can be purchased for as little as $150 whereas top quality fixtures can easily run $450 or more. Speaking with a quality manufacturer or contractor can help determine the performance/quality you might need. You should also consider new alternatives to cash purchase such as Lighting as-a-Service ("LaaS"). LaaS (see page 5) allows customers to upgrade to LED with zero upfront costs and provides immediate energy savings. 2) Assess. Take a walk through your workspace – talk to employees working underneath the light and begin to assess your existing lighting system. Are you happy with the light level? Is the current lighting layout adequate for your tasks? Do you have enough light where you need it? 3) Audit. Audit your existing system: What is the wattage and type of lamp you have in your existing HID system? How many fixtures exist and are there any existing lighting controls? How many hours each week are the lights on? Answers to these questions will help establish a baseline to calculate a simple payback. 4) Strategize. If you’re happy with your light levels and how the workspace is illuminated, then it's time to decide which retrofit strategy is best for you and your facility. On the following page our case study provides a useful comparison to help inform your decision. This is also a good time to consider lighting controls, such as occupancy sensors, in your retrofit plan. Unlike HID lamps that are incompatible with most controls due to long re-strike times, LEDs work easily with various controls - a key energy saving strategy. 5) Pick your luminaire. Generally speaking you should look for LED luminaires that exceed 26,000 lumens (if replacing 400W HID), efficiency that exceeds 140 lumens per watt, have acrylic or aluminum lenses to prevent glare, and a minimum 5 year warranty. If your mounting height exceeds 30’ or is less than 20’ than you might require more or less lumens for optimal lighting levels. Specifications:  Annual energy savings:  Payback:* 145W/18,000 lumen $16,320 10 months 140W/15,000 lumen  $16,640 1.5 years 190W/26,000 lumen $13,440 3.0 years Plug-and- play lamps By-Pass lamps New LED f ixtures Scenario: Replacing 100 metal halide lamps (400W) with LED using plug-and play lamps, by- pass lamps and new fixtures.  Key Assumptions: Annual operating hours: 4,000  Energy cost: $.16/kWh ($0.12 rate +$0.04 demand charge) Labor cost (replacement lamp): $30 Labor cost: $100/hour (licensed electrician) $30/hour (plug-and-play installation) CASE STUDY Cash Purchase *Calculated without potential rebates Lighting as-a-Service All inclusive subscriptions known as Lighting as-a-Service* (LaaS) provide customers with new, better lighting systems at no upfront cost. The customer makes a single operating expense payment (off balance sheet treatment) to the service provider for the system while retaining enough of the immediate savings to stay cash flow positive. Tenants and owners can take advantage of the financing as the pay backs are usually 3 years or less. Contracts typically run for 3-7 years (depending on the product type and customer needs) which allows this structure to work with both owned and leased facilities. During the contract period the service provider is responsible for maintaining the system and performance (in the form of saving a specified reduction in kWh usage) is often guaranteed. Plug-and- play lamps 5-years $1,360 $600 $760 $45,600 $0 Contract term: Total monthly savings:   Monthly service fee: Net monthly savings:     Savings over contract term: Upfront cost: 5-years $1,387 $830 $557 $33,400 $0 By-Pass lamps 7-years $1,120 $890 $230 $19,320 $0 New LED fixtures *Terms and conditions may vary. Subject to credit approval. SUMMARY Replacing your warehouse or manufacturing site HID lighting with LED’s offers great benefits. However, with many options to choose from it takes careful analysis to identify the best overall solution for your application. Plug-and-play LED replacement lamps are clearly the most cost effective retrofit solution. As a simple screw in bulb you save the expense and hassle of other upgrade options. These bulbs have a wide range of lumen options to satisfy almost any application and mounting height. With the lowest up-front cost of all the options, the payback is typically under 1 year. Ballast by-pass lamps are a good solution in situations where the existing site has a large percentage of failed or failing ballasts. A by-pass lamp removes the existing ballast so that the concern of on-going ballast failures is eliminated. Since the lamp is direct wired there is no ballast loss and the resultant efficiency is improved. However, since the lamp is internally driven it normally operates at lower lumen levels so is generally useful only for lower mounting heights. If high performance and a long term solution are right for you, than new LED fixtures are your best choice. While the paybacks are generally longer due to higher initial cost and labor, in return you’ll get very high efficiencies, longer lifetimes (100,000 hours) along with high quality photometric performance. Choosing manufacturers with high quality LED drivers and refractors is important to avoid issues such as glare, uneven light distribution, and LED driver failures. Regardless of the LED technology you select, a Lighting as-a-Service package can eliminate any budget issues from your LED upgrade plan. LaaS allows end-users to enjoy all the benefits of a LED upgrade, including immediate savings and better lighting, without any upfront capital expense. The flexibility of a LaaS agreement also allows this solution to work for both facility owners or tenants, as contract terms can be tailored to an existing lease.