Guide to LED

High Bays
When To Upgrade And What
To Look For When You Do
Table
of Contents
What to Look For

1 Efficiency

2 Longevity

4 Optics

5 Design

7 Controls

Appendix

I. 5 Ways To Know It’s Time to Upgrade

II. High Bay Comparision Checklist

Is it time to make the switch to LED?
It’s a common question these days,
especially as the cost of LED is now
low enough to deliver an attractive
payback. If the answer is yes, you’ll
need to know what to look for. In this
guide we’ll help you determine if it’s
time to upgrade your high bays and
the five considerations you need to
be aware of when evaluating your
LED high bay options.
Efficiency
Less wattage. Less energy. Less money spent.
Sounds simple, right? But there’s more to the
promise of high bay LED lighting. Dig a little deeper
and know what to look for and you gain far better
outcomes from your investment. Examine the LPW,
or lumens per watt, plus the combination of CRI
and CCT, or color-rendering index and correlated
color temperature, to reap the biggest savings plus
the optimal color quality that supports safety and
productivity, also important cost factors.
Like your car’s miles/gallon (MPG) rating, the LPW
tells you how much lighting you get for every watt
used. The higher the LPW, the more efficiently
your high bays operate and the more savings you
realize through reduced energy use.
Tip: In the industrial setting, aim for 140 LPW
or higher to get the greatest “mileage” from
your high bay lighting. The best LED high
bays can reach above 180 LPW.
Look For:
High Lumen/Watt Ratio
Plus:
Your ideal color rendering (CRI)
and color temperature (CCT).
1 | Guide to LED High Bays
But high LPW may not always be the best thing for
your facility. Your workers also need the right color
of light to see what they’re doing and minimize
your risks. Assess the CRI that best renders the
color of objects under the lighting, and assess the
CCT that best defines the tone of lighting. Just
because an LED high bay promotes a high LPW
does not mean you are getting what you need. A
product publishing 150 LPW with 70CRI, 5000K,
without a lens may appear “efficient” but it is far
from the ideal solution. Typical fluorescent high
bays are 80CRI so anything less is a step backward.
Where is your visual comfort for greatest
productivity? Do some areas need warm lighting?
Do some areas need to render specific colors
optimally? Together, these factors help you build
the right solution for your space.
Light Insight: Lumens per watt (LPW): a measure of
how much visible light is emitted by a source. Used
to determine the energy efficiency of lighting, where
higher LPW is more efficient than lower LPW.
 Longevity
“How long will this LED high bay light last?” It’s the
question you should always ask. So, what’s the
answer? If it’s anything less than many years, with
the corresponding proof, then you need to keep
looking. LED high bays promise a longer life than
traditional light sources, minimizing maintenance
costs (components, labor and lost production time).
It starts with thermal-management.
Heat can be brutal on LEDs. That’s because LED’s,
like all digital electronics, don’t perform as well in
the heat. LED drivers follow the “10-degree rule”
which states, for every 10 degrees (Celsius) you
lower the operating temperature of the driver, you
will double its life.
Lumen maintenance is the elapsed operating time,
in hours, over which LEDs will maintain the stated
percentage of its initial light output (L-value). Or in
layman’s terms; how long it takes for light output to
degrade to a certain point at a given temperature.
For example, a high bay rated at L70 at 100,000 hours
at 25°C tells you that the high bay will deliver 70% of
its initial light output after 100,000 hours assuming it
operates in an environment less than or equal to 25°C.
High bays operating in higher temperatures or for longer
periods of time will deliver a light level lower than 70%.
The best LED high bays have a minimal rating of L85 at
100,000 hours at 25°C ambient temperature.

This is great in cold storage facilities where LED

high bays can deliver up to 10% more light output
than stated. But for those managing warehouses
without air-conditioning or manufacturing plants
with extreme temperatures, a 65,000 lumen
high bay may only deliver 35,000 lumens or
less, resulting in inadequate illumination and/or
additional high bays to deliver the levels that will
support safety and productivity.

To determine how well potential LED high bays

perform at high temperatures, compare each high
bay’s rated lumen maintenance.

Tip: Look for high bays that separate the

LEDs and the power supply and look for heat
sinks that remove heat from the components
to ensure high L-values at different
temperatures and high LAT, luminaire
ambient temperature, factors.

2 | Guide to LED High Bays

Another key piece of longevity is surge protection, LED High Bay Lumen Maintenance and
especially in industrial and manufacturing facilities Thermal Management
where line voltages may vary frequently against
the normal specification. These variations can
wreak havoc on the longevity of LED high bays
100%
that are not equipped with adequate levels
of front-end surge protection. To max out
your maintenance savings, consider where the
luminaires will operate. Work with professional Threshold
lighting engineers and agents who can help 70%

you design ahead for long-lasting lighting in

challenging conditions.

Light Out put

Light Insight: The best thermal-management
Required Lighting
designs consider not only the heat generated by
the LEDs, but also from its power supply. It then
dissipates all heat effectively to ensure longevity
of the entire system. L70 (hrs)

A note on quality: While LED tubes have Time

a lower initial cost than LEDs, they quickly
degrade, requiring expensive maintenance
that leads to a substantially higher total cost Superior Thermal Management
of ownership. When evaluating your high bay Average Thermal Management
lighting options, be sure to look for a system with
the lowest total cost of ownership. Poor Thermal Management

Look For:
High L-values at 100,000 hours

Plus:
Long LED driver life (100,000 hours) without
a steep drop-off in higher temperatures

3 | Guide to LED High Bays

Optics
Visual comfort is critical for safety and productivity. Quality in a LED high bay is about more than
You must have the right lighting for each specific efficiency; it’s also about getting the right light with
task to reduce eye strain and glare that can quality optics so workers can optimize each task.
lead to problems. That means the ideal mix of
vertical and horizontal illumination, at whatever
distribution patterns – focus, narrow, medium or Tips: Choose diffused or prismatic lenses
wide – are required. to reduce glare and jarring contrasts which
lessens eye strain and helps promote a
So, what else defines “the right lighting”? The safer environment.
Illuminating Engineering Society (IES) recommends
light-level standards, prescribing foot candles
Light Insight: Vertical illumination refers to
for a particular space type as well as uniformity
lighting of the vertical plane (think: racks in aisles).
ratios, the ratio between minimum and maximum
Horizontal illumination refers lighting the horizontal
foot-candle readings. And, your own environment
plane (think: your manufacturing floor).
dictates other considerations. Uplighting, for
example, combines with downlighting to mitigate
the cave-like nature of a high bay application.

IES recommended light levels IES recommended light levels

for assembly manufacturing for material handling

Application Hortzontal Vertical Uniformity Application or Hortzontal Vertical Uniformity

or Tasks (fc) (fc) Tasks (fc) (fc)

Difficult 100 100 3:1 Loading 10 3 3:1

Picking stock,
Exacting 30 30 3:1 10 5 3:1
classifying
Wrapping,
Simple 3 30 3:1 packing, and 30 15 3:1
labeling

Look For:
Diffuse or Prismatic Lenses

Plus:
Optical features that provide visual
comfort for every task

4 | Guide to LED High Bays

Design
Knowing not all LEDs are created equal, you can
venture into one more area of differentiation: Tip: Choose LED high bays with an ambient
system design. Quality LED high bays ensure temperature rating between 40 0C and 550C
the best performance because they’re designed depending on the space.
for your space. They have features industrial
environments need, such as high-ambient
temperature ratings or IP, Ingress Protection, A Note On Quality: Cheap high bays are
ratings. They’re easy to work with and install. Their designed to be thrown away once they go
components are easily accessible for upgrades and out making them little better than traditional
they’re designed for the future. sources. So, look for high bays that are designed
to swap out components and use as few screws as
If you work with a professional engineer and lighting possible to get to their internal components.
agent who takes time to plan and design around
efficiency, longevity and optics, you’ll realize the
best that LED high bays can offer. You’ll maximize
energy efficiency and save the most on maintenance
and long-term luminaire replacement costs. You
might further boost your bottom line with optics that
enhance workplace operations.

Look For:
Proper Ratings For The Space

Plus:
System design that facilitates
long-term ownership.
 Light Insight: The IEC (International
Electrotechnical Commission) uses the term
“International Protection” or IP to define the
environmental protection of an enclosure. The IP
rating system, by means of a two-digit number,
represents the degree of protection against ingress
of dust and moisture. The first digit defines the
First Digit Degree of protection against solid objects
0 Non-protected
1 Protected against a solid object greater than
50mm such as hand
2 Protected against a solid object greater than
12mm such as finger
3 Protected against a solid object greater than
2.5mm such as wire or a tool
4 Protected against a solid object greater than
1.0mm such as wire or thin strip
5 Dust-protected. Prevents ingress of dust
sufficient to cause harm
6 Dust-tight. No dust ingress.
6 | Guide to LED High Bays
level of protection against solid objects while the
second digital defines the level of protection against
moister. The higher the digits, the greater the level
of protection. For example, a high bay that is rated
IP66 is rated to be dust tight and protected against
when immersed in water between a depth of 150mm
to one meter.
Second Digit Degree of protection against water
0 Non-protected
1 Protected against water dripping vertically
2 Protected against dripping water when
incident up to 150 from vertical
3 Protected against water spraying at an angle
of up to 600
4 Protected against water splashing from
any direction
5 Protected against jets of water from any direction
6 Protected against heavy seas or powerful jets
in harmful quantities
7 Protected against harmful ingress of water
when immersed between a depth of 150mm
and 1 metter
8 Protected against submersioin. Suitable for
continuous immersion in water
Controls
Local codes now spell out the controls strategies
that should (or must) be used to greatly reduce
the consumption of energy. The lighting industry
accommodates these strategies, but at varying levels
of compatibility with existing lighting solutions.

At one end of the spectrum are standalone sensors

that adequately meet codes. At the other end are
feature-rich, factory-integrated control systems –
many of which exist as part of large-scale lighting
and control networks – that are easy to configure.
And if they’re easy to configure, it’s easy for you
to enjoy all the benefits of lighting controls –
significantly more energy savings, longer luminaire
life, flexibility to adjust as your operation evolves,
and improved working conditions for your team on
the production floor.

Tip: Choose controls that work seamlessly

together across all areas of the facility, from
office to industrial to outdoor.

Look For:
Controls that help you meet local codes

Plus:
Solutions that are factory-integrated and
easy to use.

7 | Guide to LED High Bays

Light Insight: Implementing multiple levels of control strategies saves money by reducing energy
consumption by as much as 70%. The following table explains these controls strategies and their potential
to save energy.

Strategy Description Savings

Varies the light output of the lighting system over a continuous range
from full to a minimum light output without flickering, in imperceptible
Continuous Dimming Situational
steps. Reduces energy consumption without disrupting occupants and
often satisfies code requirements for bi-level or multi-level lighting control.

Automatically regulates the use of electric lighting in response to

Daylight Harvesting the amount of daylight available. Saves energy while maintaining 5%-15%
consistent illumination for occupant comfort and safety.

Extends a lighting control system to also control an HVAC system

HVAC based on occupancy or time of day. Helps centralize building Situational
management and reduces energy consumption for additional savings.

Selectively reduces the load of a system on a temporary basis to

Load Shedding 5%-15%
avoid peak pricing.

Adjusts lamp power over time to maintain constant light output as

Lumen Maintenance Control lamps age and dirt accumulates in luminaires. Saves energy early in Situational
the life of a system and extends lamp life.

Regulates the operation of lighting or other equipment by detecting

the presence or absence of people within a space. Ensures electricity is
Occupancy Sensing consumed only when the space is in use and can be extended to HVAC 10%-30%
and/or plug load control to help centralized building management.

Enables users to adjust their illuminated environment to fit their

Personal Control personal preferences within a space. Maximizes occupant comfort 5%-25%
and can increase productivity.

Extends a lighting control system to control plug loads based

on time of day, occupancy or a demand response signal.
Plug Load Control Situational
Helps centralize building management and reduces energy
consumption for additional savings.

Controls lighting, equipment or other building management systems

based on the time of day or astronomical event. Automates energy
Scheduling 10%-40%
savings by delivering the desired light levels throughout the day without
using unnecessary electricity.

Programming the maximum light output of an individual or group of

Tuning luminaires to provide the desired amount of light for a space, task or 5%-15%
area. Extends lamp life and enhances lumen performance over time.

Potential cumulative savings 40%-70%

8 | Guide to LED High Bays

 The Next Steps
A high bay LED lighting system should
be treated like any other asset in your
industrial facility. Using this guide is your
first step! Next, contact a local lighting
agent with the experience and expertise to
assess your current lighting system, assist
with lighting design, and help you evaluate
your options so you get a tailored solution
that meets your high bay needs.

Yes! I want my local lighting agent

to contact me for a free lighting
assessment, assistance with my lighting design,
and/or help evaluating my high bay options.
Time to Upgrade Your High Bay?
Answer these five questions to help determine if you should start
looking for new high bay lighting.
1. What type of high bay lighting do you
currently have?
If you have HID or fluorescent high bays, it’s time
to upgrade because you’re missing out on the
benefits of LED lighting.
ƒƒ Energy Savings: LED uses at least 50% less
energy than traditional sources.
ƒƒ Maintenance Savings: Quality high bay LED
solutions can last 100,000 hours or more. That’s
over 10 years of 24/7 usage.
ƒƒ Code Compliance: As building energy codes
become more restrictive, high bay LEDs
support compliance.
ƒƒ Controllability: high bay LEDs can easily be
integrated with automated digital controls that
dim or turn lights on and off based on time of
day, available daylight, occupancy, load shedding
events and more.
ƒƒ Integration with Other Systems: because high
bay LEDs are digital, they can be linked with other
BMS systems to create a single building system.
4. Are any of your high bays out right now?
If yes, it’s time for an upgrade. Dysfunctional high
bays can result in poor productivity because your
crew cannot see properly to get the job done
quickly. But more importantly, insufficient light can
result in safety hazards.
5. Are your light levels low making it difficult
to see?
If your crew can’t easily see lot numbers from the
top rack to the bottom shelf, or with the clarity
they need around dangerous machines, it’s time
for an upgrade. HID and fluorescent high bays
dull quickly requiring maintenance and bulb
replacements. But while you’re waiting for a
handful to go out, your production floor can get
dark. The Illuminating Engineering Society (IES)
recommends anywhere from 20 - 100 foot candles
for most industrial high bay applications to ensure
adequate lighting and safety for workers. Not
sure? Contact a local lighting agent to do a free
assessment of your plant.

2. Are your high bays always on?

If they’re always on, it’s time for an upgrade. You
can reduce your energy consumption by up to 80%
in some cases by adding controls that will ensure
your lights only stay on when you need them to.

3. Are your high bays controlled via manual switch?

If the only way to turn off/on you high bays is with a
manual switch, it’s time for an upgrade. Automated
controls can dim and turn lights on and off based
on time of day, available daylight, occupancy, load
shedding events and more so you can realize
energy savings, stay compliant with building energy
codes and save time.

I | Guide to LED High Bays

 High Bay Comparision Checklist
Use this checklist when evaluating LED high bays so you can identify the best solution for your specific needs.

Category Characteristics Fixture A Fixture B Fixture C

Lumens

Watts

Efficiency LPW

CRI

CCT

TM21 (Lxx) at 60,000 hours at XX temperature

TM21 (Lxx) at 100,000 hours at XX temperature

Longevity
Driver life (hours) at xx temperature

Maintains lumens at ambient temperature (LAT factor)

Optic material (glass/polycarb/acrylic)

Optic texture (flat/prismatic/diffuse)

Optics
Distribution type available (focus, narrow, general, etc.)

Provides adequate light for vertical illumination (Y/N)

Proper ratings (Wet/IP/NSF/Haz)

Proper temperature ratings

Design
Maintenance-friendly features

Weight

Factory installed (Y/N)

Networked available (wired or wireless)

Controls
Non-networked available (occupancy / photocell sensors)

Ties into building management system? (Y/N)

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