S2HBwRGBW - High Bay Retrofit Module with embedded RGBW LEDs

In-house designed High Bay Retrofit module with embedded RGBW LEDs.  The product was designed for a particular customer that wanted to upgrade forty-seven 400W Halide based lighting fixtures with a modern LED equivalent, but had to accommodate four different fixture styles: recessed, pendant, large wall mount, and small mount mount.  All of these fixtures were installed 10m (about 30 feet) above actively used public spaces.  Full replacement of the fixtures was considered, however, the cost, disruption, and High-bay/High brightness LED reliability/longevity concerns stimulated the customer to approach us for a solution.  The result was a custom designed LED lighting module that could be easily retrofitted into the existing fixture housings which reduced the overall cost, building disruption, and significantly exceeded the customer's energy efficiency requirements:

The result was a single design that inckludeused within all fixtures styles which minimized upfront and long term costs.  Special design attention also addressed may of the weaknesses of off the shelf high-bay solutions in terms of power consumption, heat generation, and no changes to existing electrical and mechanical infrastructure which would have extended the project timeline dramatically. 

• Utilizes start of the art Ceramic backed chip-on-board (COB) High Power LED technology that maximizes light output and reduces energy consumption.  Multiple LEDs with each having their own driver was used to minimize 100% failure of the fixture's primary lighting system. Maximum light output is 20000 lumens.

• High efficiency RGBW (Red, Green Blue, and optically pure White) LEDs were used with suitable lenses to allow the fixture to also be used for special effect, seasonal, or Civic pride lighting applications. Maximum RGBW light output is approximately 1600 lumens.

• Custom designed micro-controller based 8-channel LED Driver with an on-board RS485 communication interface providing support for DMX512 ( or Bacnet MSTP, Modbus, etc).  All LEDs are fully dimmable in 256 steps with 0% dim level truly turning off the LEDs.  On-board temperature monitoring along with direct control of an external cooling fan in cases where convection cooling is reduced such as enclosed cavities.  Wireless control such as Wifi, Wifi-mesh, Bluetooth, and Bluetooth Mesh are supported with an external add-on module.  On-board USB interface is included for device's initial setup/provisioning, diagnostics, and setting minimum and maximum light levels, etc.

• Addressing reduced reliability and longevity of typical quality high power/lumen output LED fixtures (average lifetime of 30000 hours using LM-70 specification), significant attention was paid to the device's thermodynamic profile.  Advanced thermodynamic components were used including specialty aluminum alloys, heat dissipation/transference items, and other design considerations reduced the critical high power LED components operating temperatures by over 40C (surface temp from a rated 138C to 90C, case temp from 90C to 56C) and so greatly extended the LED lifetimes.  On-board real time temperature measuring and active cooling was also used in cases of minimal to no convection air flow applications.

• Assembly uses a high quality CSA/UL approved power supply accommodating all standard electrical voltages ranging from 120VAC to 480VAC.  Overall power consumption is based upon the fixture's setup parameters, light levels, etc. and ranges from 10W to 200W.

• Assembly can be retrofitted into several different fixture housings using tailored mounting plates that are affixed to various mounting locations.  To date four different lighting fixture styles have been upgraded with the module including recessed, pedant mount, and two different size wall mounts.  Other applications include "torch" style fixtures (light attached to vertical pole) with a suitable diffuser attached to the surface, etc.

• Total fixture and controller cost is typically much less expensive than what is available off the ehelf, but with more features, functionality, integration capability, and superior energy efficiency.  In fact depending upon the existing fixture housing's cavity loss, the module can reduce energy use dramatically as compared to Halide or Mercury Vapor based lighting solutions.  In the customer's case of their 400W Halide based fixtures (450W once the ballast is included), the S2 module reduced the power consumption to 18W ... which is a 96% reduction.in energy used.  For this customer this translated to a monthly savings of $800 over the 47 fixtures that were upgraded with S2's module.