LED Lighting for Woodworking Shops and Projects · November 11, 2017 Practical LED Lighting –Ted...

LED Lighting for WoodworkingShops and Projects

November 11th 2017Ted Schaefer

Shoplight Solutions, LLC

November 11, 2017 Practical LED Lighting – Ted Schaefer, Shoplight Solutions LLC Slide 2 of 42

Outline: Practical LED Lightingfor Woodworkers

Practical aspects of lighting a work shop with LED lighting. • Case studies• LED product trends related to shops

Terminology review: Lumens vs Watts, CRI, CCT, IP67, UL, DLC, etc…

Planning your lights:• How much light do you need? • How does the light requirement translate to the number of fixtures?• Electrical requirements, dimming

New fixtures, retrofit existing fixtures or make your own?• Lighting Products, T8, Strips, etc.• What differentiates LED products?

Demonstration: Retrofit 4’ and 8’ fixtures

How LED lighting can be used with your projects.

Raffle 2 pairs of 4’ LED tubes.

Q&A - View samples of LED lighting


Thanks for Second Opportunity

At the March meeting I was honored to present Introduction to LEDs. Today will be a more practical take on how best to light up your shop and integrate LEDs with your projects.

Since March, I have had the pleasure of visiting several WOCO members in their shops. It has been a great learning experience for me about woodworking. After discussing appropriate the type of lighting, I have delivered the products and helped install them. I have come to understand that this service is what distinguishes Shoplight Solutions.

Ask questions any time or in the Q&A at the end.

Both the March and November presentations are posted at: www.shoplightsolutions.com/document/presentations

For additional info contact me at: 614-668-8972 or [email protected]

I will stay as long as permitted and people are interested.

http://www.shoplightsolutions.com/document/presentations


Just Preaching to the Choir….

Love/Hate

Pros: Compared to incandescent lights, fluorescents are a great. I put them up everywhere – basement, garage and I eliminated every incandescent with CFLs. They made sense, lasted longer, provided more light and saved energy.

Cons: Seemed like a constant battle against black ends, diminished light, burnt out ballasts that were more expensive than the original fixture. You need to twist the bulbs occasionally for them to make contact. You reduce their life by on/off cycling (not so with LEDs).

Also: Hum, slow start up, poor cold performance, color rendering was bluish, not good for vibration, mercury requires recycling.


Case StudiesLarry Ottinger Farmer

Larry is my cousin, a farmer in eastern TN, is an official in his church. A couple months ago while visiting he asked about LED light for the church and I sent him 4 tubes to experiment with.

Thursday night he called from the church attempting to install the lights overwhelmed by all the wires and ballasts. I told him, power off, cut everything. A couple more tips, and 10 mins later he sends me this picture with his son Jack.

He called, excited to find that the 2 bulbs produced more light than the 4 old florescent tubes. He decided that he would use the remaining 2 bulbs in another fixture. My potential sales plummeted by 50%. ☺

He replaced 4x 32W bulbs with 2X 14.5W LED tubes. Disabling the ballast saved some more. He reduced his electric load by 80%. It’s rewarding when your relatives begin to

understand why you have a passion for LEDs.Not just the crazy guy who should be retired.


Case Studies -Bob Cole WOCO

Bob is tall, and his shop has a low ceiling with single “point source” bulbs hanging down that were often broken by maneuvering a long board.

We worked through some possibilities with calculations and drawings, arriving at a “make your own light solution”using aluminum channel with diffuser and 6500K CCT LED strip.

This custom light has a ¾ by ¾ cross section. We ran 150’ of it in a pattern that would provide well distributed light.

We ran additional 6 foot sections over key equipment like the chop saw to eliminate any shadows and make fine measurements easier to read.

I delivered the product to Bob in Hebron and helped install the first 2 “runs” as training.

The shop feels much taller and brighter and there is no risk of exploding CFLs. There are no “light behind the back” shadows.


Case Studies –Impression Products

Impression Products, Charleston, WV, is the nation’s leading supplier of refurbished laser cartridges. Their warehouse was lit by several rows of 2-bulb, 8’ florescent tubes - many bad tubes and ballasts. The warehouse was dim and depressing, and as a consequence, in disarray.

I was contracted to do the LED conversion using SS’s 5280 lumen 8’ bulbs. I converted one fixture and they decided to cut the number of bulbs in half – one per fixture instead of 2 per fixture.

The warehouse is now much brighter than before using 25% of the electricity. The unexpected effect was the positive impact on worker moral.

Previously they were smashing the florescent bulb with the fork lift. The new bulbs are much more impact resistant and I raised the fixtures above the rafters as well.

We tell everyone about you and your lights and

how awesome they are!


Case StudiesMuirfield Village

Muirfield Village’s maintenance facility was very dim! I visited the shop with productsamples so they could see the difference.

They placed a large order and I left a boxof 4-footers for their tool room. Their shoppeople installed the bulbs without instructions.

Muirfield was building a new high bay garage andhad already purchased florescent fixtures. Sincethe building plans were approved, manager Walter Zeier, would not change the lighting.

However, soon after Muirfield’s first order, Walterplaced a second order for 4-footers. Before he put up the new fixtures, he disabled theballasts and installed LED bulbs in the newfixtures rather than purchase much cheaperflorescent tubes.

Walter is available as a reference. They purchased 146 T8 tubes.


Case Studies

This was fun. An architectchallenged me to provideambient light on top of awood grid for a new donutshop at 656 High Street,Worthington, OH next toGraeters.

Originally the requirementscalled for color morphingbut that was a little expensivefor the new operation.

The effect with warm white led strip was very nice. The should have used LED Edison bulbs.

These are really great cake donuts.I recommend that you get somefor the game. Try bacon-maple! Get a free donut on your first visit.

Remote dimming, 7-year power supply


Case Studies - Woodworking Shops

John Herrel’s basement shop head challenged. After a visit he chose to create his own lights using scrap melamine and SS LED strips eliminating several large CFLs.

I visited Charles Murray in Grove Port to show him product options. He purchased several of the 14.5W, 2100 lumen bulbs for his commercial fixtures, discovering they had “shunted” tombstones. I located a nearby source of non-shunted tombstones and brought them back to the shop, seeing the job through – beginning to end. I now offer a technical paper regarding the difference on the Shoplight website and stock non-shunted tombstones.

Larry Crane wanted to upgrade his fixtures, but after a visit, we decided to add some fixtures from Sam’s club over the areas where he wanted more light. Theme: tailored solutions and low cost.

Bob Plaumer’s basement shop was not bright enough. I retrofitted 9 fixtures with his help.

Several WOCO members have purchased LED strip for their fixtures.

Ralph Devine remodeled a farm building as a shop with new lights. I will be using his project as an example for planning a lighting project.


Possibilities > Terminology

Now you have seen some examples – possibilities.

To get from possibilities to practical applications, we need to some terminology that will put us on the same page.

Terminology > Practical Applications


LED TerminologyLumens Not Watts

Incandescent lights were sized by Watts*which is a measurement of the electricity they use. Over time this equated to the amount of light they produced. Now it is common to hear “60W equivalent” for both florescent and LED lights.

Lumens is an exact measure of the total light output – a more accurate measurement than Watts or Watt equivalence. A 60W incandescent bulb produces about 800 lumens, a 100W blub produces 1600 lumens.

Lumens per Watt is a common measurement of lighting efficiency. 160 Lm/W is currently the higher end. SS T8 4’ tubes are 145 Lm/W.

Lumens per $ is a measurement of the cost effectiveness of lighting.

Quantifying light

*“Watt or “W” is generally capitalized because it is named after James Watt, a Scottish engineer who in 1763 designed the modern steam engine with a crankshaft. Watt is a unit of power not light (1 Horsepower = 745.7 watts)


LED TerminologyFoot Candles

Footcandles are used by lighting professionals to calculate light levels. A footcandle is defined as the illuminance on a one square foot surface from a uniform source of light.

Later, we will use footcandles to calculatethe light required in a work shop.


LED TerminologyCorrelated Color Temperature (CCT)

Correlated Color Temperature (CCT) in degrees Kelvin (K) describes light’s color. As you heat a piece of iron, it glows red, then white as it gets hotter.

An incandescent blub produces light with a glowing filament at about 2700K.

We actually see better for tasks with a brighter white, almost bluish, like being outside on a bright day.

Bluish light is a wakeup call to our bodies.


LED TerminologyColor Rendering Index (CRI)

A Color Rendering Index (CRI) value of 100 is equivalent to daylight.Low-pressure sodium lighting has a negative CRIFluorescent lights range from about 50 for the basic types. Typical florescent bulbs have large gaps in their spectrums which accounts for the poor CRI and contributes to eye strain.

CRI 100

CRI 50-70

CRI 75-95CRI 75-95

Tip: You can mix types of LED strip to achieve better CRI

Under low CRI and high CCT red tones in wood wash out, other colors not true


FYI – Spectrum for Horticulture

Blue and red plus a little white. Different plants in different stages of growth benefit by tuning these colors. LEDs are coming on strong in horticulture.


LED TerminologyPhotometric Data

Beam Angle

Flux at distance from Light

1 Lux = 0.092903 footcandleLux is metric


LED TerminologyIP Rating

Ingress Protection (IP) Rating determines degree of protection against the ingress of dust, solid objects and moisture into an enclosure. The letters “IP” are followed by two numerals: 1) Objects and Dust, 2) Water and Moisture

IP68

Not Rated

IP65

IP54

IP68


LED TerminologyIK Rating

00 Not protected

01 Protected to impact of 0.25kg mass dropped from 56mm above impacted surface.

.

.

.

10 Protected to impact of 5kg mass dropped from 400 mm above impacted surface.

IK is the impact rating – generally not relevant to lights except severe duty, explosion proof, etc.


LED TerminologyL70 Life

What do you do with a product that

lasts 50,000+ hours???

Extrapolate!

LEDs and Power supplies in a light can vary in life expectancy. LEDs if not pushed aregood for 50K-100K hours, while power supplies can be 15K-100K hours. This is the reasonwhy commercial power supplies are expensive.


PlanningThings to Know and Consider

General Goals of ProjectDYI or Contracted – how big is the project?Improve working conditions - eliminate shadows, flicker, CCT, CRISave electricityReduce maintenanceLook nice, instant on, no hum, cold weather

Type of tasks and brightness required (IES footcandle chart)Hours of operation, 12 hrs per day requires a better lightCost of maintenance? (Electrician required? Man lift vs 6’ ladder?)

Mounting height - impacts lumens, installation cost, maintenanceArea square ft and dimensionsEnough existing light when lights working properly?Available circuits and switchesControls can do more with LEDs than fluorescents

DimmingMotion sensing (locations that are randomly occupied for short periods)On/OffRemote control (useful in high places where running switch may be difficult)


PlanningIf Upgrading Existing Lighting

If using CFL point source lighting and ceiling is under 10’ consider new fixtures for distributed lighting and less glare.If you have existing florescent fixtures and they produce reasonable light when working properly, then retro fitting is the best option.

LED strip is your least expensive retrofit but will create pixilation.T8 Tubes are best option, saving installation time and are easy to replace. T8 Tubes are available in 1800 to 2600 lumens so you can create a brighter shop.Shoplight’s 2100 lumen, 14.5W, 5000K, ballast bypass tubes fit most scenarios, making your shop brighter and at least 5 years of life.

If you have head room issues consider a custom low profile light using LED strip, aluminum channel and diffuser. Consider light panels if you have a suspended ceiling and/or headroom issues.If you have a high ceiling, consider commercial high bay or low bay lights, especially if you havelong hours of operation. If you have existing HID lighting consider a Corn Light.


Conversion of 4’ Shoplight

If she can convert a shoplight…

Recycle at:• SWACO (614) 294-1300• Batteries Plus

Convert or New?• Reuse/recycle – Environmentally friendly

• Don’t have to change mount – Save time

• Conversion cost less

• New: looks nicer.

Convert Using SS LED Strip Kit• https://www.youtube.com/watch?v=VcltCawdAsE

Convert Using LED tube w/o Ballast

https://www.youtube.com/watch?v=VcltCawdAsE


T8 Tubes for New and RetrofitT5 too

LED Tubes are now the most common florescent fixture upgrade.They are now price competitive with LED strip.US distributionBetter light distribution5 year warrantyThey are available in:

• T8 or T5• 2’, 4’, 8’• Ends: G5, G13, FA8, R17D• Efficiencies from 100 lm/W to 145+ lm/W• Lumen ranges from 1100 to 6000 per tube• Type A, B or C• Single end supply or double end power supply

Affordable, time saving, easy to replace4’, single end, 5000K, ballast bypass (Type B) is most mass produced and the one we stock.


T8 Tubes for New and RetrofitUL Types


T8 Tubes for New and RetrofitUL Types A and B

Type A tubes are “plug-and-play”. They contain internal drivers that operate with the existing ballast and do not require changes to the fixture or wiring. Ballast compatibility can be an issue. They are more expensive than ballast bypass tubes and you are required to maintain a working ballast. The ballast, a point of failure, also consume additional power making these less efficient than type B.

Type B tubes are the most popular but you have to wire line voltage directly to the tubes, bypassing the ballast. This is easy to do, but does require additional effort. There are two configurations of type B: both line voltage and neutral are connected to one socket and the other end is dead. This means requires a non-shunted (non-shorted) socket. Using the other type B configuration, “double ended” you wire line voltage to one end and neutral at the other.

double ended works with shunted holder

Single end works with non-shunted holder


T8 Tubes for New and RetrofitUL Type C

Type C a packaged system of one, two or more bulbs and a matched power supply. These are the most efficient systems but also require you to bypass the ballast. (A good thing IMHO)

You lose the ability to swap out the tubes sincethey are a matched set from one vendor.

Our new magnetic system is similar but eliminateshaving to use the tombstone holders. Foregoingthe T8 tube construction, they allow you chooseyour own cover milky, clear or none. With a T5cross section, they will work equally well on an existing fixture, one you design or with no fixture at all.


PlanningIf New – Starting from Scratch

Whether you are removing all of your old fixtures or lighting a new space, you will have to calculate/estimate the lumens required.

Using the Illuminating Engineering Society (IES) foot candle lighting guide, partially shown on slide 13, we see the recommended footcandles at the task surface is 100 fc for detailed work. This is a reasonable target for wood working.

Number of Luminaires = [Footcandle Target x Room Area] / Lumens per Luminaire

Using Ralph Devine’s new space of 31’x21’ and 3 different scenarios using 8’ fixtures we get the calculations on the next slide.

Note: if the space is used for finishing wood and you want to view true colors, you should consider a warmer light 3000K, with a higher CRI than 85.


Calculations

Fixture type 11,200 lumen 8400 Lumen 8400 Lumen

Ceiling Height in feet 10 10 10

Work surface height in feet 2.5 2.5 2.5

Distance to work surface in feet 7.5 7.5 7.5

IES recommended FC for detailed Assy 100 100 100

Building Sq Ft 21x31 651 651 651

Lumens per fixture 11,200 8,400 8,400

Coefficient of Utilization 0.8 0.8 0.8

Rough est fixtures FCxSqFt/Lumens 7.00 10.00 10.00

Watts per fixture 80 60 60

Fixtures in layout 8 8 10

Total Wattage 640 480 600

Total Lumens 89,600 67,200 84,000


Calculations / Considerations

I liked the middle choice at 8400 lumens per fixture, which uses a new linear light “body” prewired for LED 4’ tubes. This takes advantage of the lower cost, mass produced 4’ tubes compared to 8’ tubes.

We chose the lower fixture count, 8,instead of 10 because we could add more over specific work tables and pieces of equipment if needed.

I came up with a layout thatdistributed the light evenly.


Wiring 8’ fixturesRetro and New

This is the new fixture used for Ralph Devine’sproject. It ships with loose tombstones that snapinto place.

Let’s put 4 bulbs on it and see what it looks like.

The second 8-footer use a typical 8’ bulb with single pins. One end is spring loaded to hold the bulb. I will install a 3600 lumen bulb and a 5280 lumen bulb side by side. Let’s see what it looks like.

In March, 8’ bulbs were just becoming more available in the US, becoming affordable. In March I suggested LED strip for 8’ fixtures. It is still a good solution, but the tubes are better, even if a little more costly.


Dimming

Incandescent lights work with triac dimmers that lower the voltage to the bulb

Lowering the voltage to the LED power supply doesn’t work, however there a few newer bulbs and power supplies that support triac dimming.

For a Constant Voltage power supply, the output must be modified either by voltage adjustment or better using Pulse Width Modulation (PWM).

LEDs can be easily cycled on/off at 20,000 times per second. By electronically chopping the on/off time, you can precisely reduce the LED output.

Some power supplies have integrated PWM controlled by a 0-10V signal that can be controlled by a special wall switch or rheostat. Most panels come with dimming power supplies. Note the donut shop system included remote controlled dimming using 0-19V.

Inexpensive PWM Dimmer

If you want dimming for a LED bulb make sure the bulb is labeled dimmable and the wall switch says it works with LEDs.

0-10V Dimmer


Panels

1x4, 2x2 and 2x4 panels are now readily available for little more than a shop light fixture.

They provide even light with no glare.

Panels are thin – about ½ inch. New driverless panels don’t even have the power supply bump.

Most often they have 0-10 volt dimming.

Mounting options: Ceiling grid, suspended or flush mount.


Other Controls

One of the faults of typical industrial lights is that you can’t quickly turn them on and off. Have you been at a sporting event when the light turned off and it took 15 minutes to turn them back on? LED’s turn on instantly at full brightness even in cold weather.

Motion sensors can turn on LED lights only when needed. If you have anarea of a shop or warehouse that only has random activity, then put it on a motion sensor (a CA requirement).

A street light application leaves the LED lights on ½ brightness, but when a car comes by they switch to full brightness.

A photo control can be more than on/off. It can sense the amount of ambient light coming through the windows and adjust the LED lights to lowest ideal.

Controls can be a computerized and controlled by WiFi to operate in groups.


Make Your Own LightLight where you want it without commercial fixtures


Make Your Own LightParts

Using a power supply and LED Strip to retrofit a florescent fixture is a form of “make your own”

Using these connectors and clips you can mount a T8 LED tube anywhere

Packaged with magnetic mounts


Light and Wood – Ted’s Uber Desk


Light and Wood


Wrap up

Questions and AnswersDrawing for T8 Tubes

Thanks!

LED Lighting for WoodworkingShops and Projects

November 11th 2017Ted Schaefer

Shoplight Solutions, LLC

LED Lighting for Woodworking Shops and Projects · November 11, 2017 Practical LED Lighting –Ted...

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