Highbays are all the same, aren’t they? Actually, the answer is no – there is a big difference between even conventional LED highbays.
When it comes to more demanding environments, you need to take extra care when making your choice.
This review is about luminaires which are suitable for more demanding environmental conditions, such as high temperatures, corrosive atmospheres, cold stores etc.
One aspect of industrial lighting that is often forgotten is that the ambient air temperature around a highbay may be considerably higher than at a ‘normal’ ceiling height.
It’s worthwhile actually measuring the air temperature at the height the luminaires will be mounted and then verifying that the luminaire is suitable for use at these elevated temperatures.
Some of the highbays reviewed will withstand temperatures higher than 70C.
If the environment is dirty or dusty, check what Maintenance Factor, MF, has been used in the lighting calculations.
The LEDs might lose 30 per cent of their output during the life of the installation (that’s what L70 means).
Better quality luminaires may have L80 or L90 for their rated life.
The light output is further reduced by the accumulation of dirt or dust on the outside of the luminaire.
Dust can also get inside the luminaire if it isn’t sufficiently IP rated. If the dust happens to be black tyre rubber or cardboard, you can imagine what this does to the light output.
I have seen MFs of 0.9 (only a 10 per cent light loss over life) used in a calculation which is either unforgivable ignorance or, more likely, mis-selling.
In industrial areas, BS EN 12464 allows you to use a light source with a lower colour rendering than normal, depending on the use of the space.
You need to take care though. High lumen output and energy efficiency is often achieved by using LEDs with a low CRI and a high colour temperature, CCT, maybe as much as 6500K.
I have seen installations where the capital cost and payback look brilliant but you wouldn’t actually want to work there.
Finally, if you are completely new to designing lighting for an extreme environment, there is a great deal of useful advice in the SLL Lighting Guide 19 Lighting for Extreme Conditions.
Eaton Crouse Hinds
The name Crouse Hinds is usually associated with explosion protected luminaires, especially those using HID lamps. The new Pro series is designed for non-hazardous areas but which still might normally be considered to be demanding environments. It has both CE and UL Certification and will operate from -40C up to 65C. The body is die-cast aluminium with an epoxy powder coat.
The IP66 Champ Pro looks like a conventional discharge lamp highbay with deep, vertical cooling fins and the driver compartment on the top. The nominal light output ranges from approximately 3,250 lm and 26W to 11,100 lm at 91W. The standard unit is 5000K with a CRI>70. There is also a 4000K version and a 3000K with a CRI>80. It can be fitted with either a diffuse glass or clear polycarbonate lens.
Three beam distributions are available (NEMA Types I, III and IV) and there is a huge range of mounting brackets to suit just about any type of fixing.
I am reminded of the scene in Crocodile Dundee where the hero says ‘that’s not a knife, THIS is a knife’. Except that I would substitute ‘THIS Glamox i90-P is a highbay’. It’s 515W, weighs 28kg, three times as much as some highbays. It emits over 55,000 lumens (smaller wattage versions are available) and can operate in ambient temperatures from -40C to + 60C. Four beam widths are available and it is rated at IP65, IK08. There is a toughened glass front lens or impact resistant acrylic. It has a CRI >80.
The drivers are in sealed, vertically mounted, finned aluminium enclosures which are totally remote from the LEDs.
Whenever you want a solidly made, long lasting highbay, you should always consider what Holophane has to offer. The well-established IP65 Prismpack is available in a range of sizes that can deliver from 10,000 lumens up to a whopping 120,000 lm. This is achieved by combining a single LED module (up to 20,000 lm) in groups of one to six.
The standard version will operate from -25C up to 50C and Holophane offers a high ambient version suitable for 70C albeit the output at that temperature is a ‘mere’ 60,000 lumens.
Of course, Holophane is renowned for controlling the light using prismatic optics. Its first patent was 120 years ago for a diffusing globe made of borosilicate glass. The latest Prismpack builds on this with the introduction of miniature, faceted reflectors around each LED engine. The LEDs are set deep in the reflector thus minimising glare.
The covers are made of clear or prismatic glass which has a great deal more resistance to corrosive atmospheres and UV than conventional plastics.
Is 85C extreme enough? It is hard to imagine an area with an ambient temperature this high but the Centaurus can illuminate it for you. You do need to install the driver remotely but this can be up to 50m away somewhere ‘cool’, like 55C, or less.
The LEDs have to be slightly under-run when at 85C but you can still achieve over 23,500 lumens per luminaire. That’s twice the output of some highbays. The standard Centaurus range is up to 56,000 lm at 60C.
The Centaurus is rated at IP65 and with the polycarbonate cover has an impact resistance of IK10. CCTs of 3000K, 4000K and 5000K are available all with a CRI >80.
The IP65, IK07 GentleSpace is available in a range of versions suitable for high temperatures (70C), food and beverage areas, pharmaceuticals and agro-chemicals, ATEX2/22 explosive zones and swimming pools.
Lumen output ranges from 13,000 to 35,000lm and so the GentleSpace could easily be used in medium to large spaces. Typical wattages are from 84 – 230W. There are five beam spreads available including one specifically for racking.
The standard offer is either 4000K or 6500K, both with a CRI> 80. The high temperature version has a glass cover.
Strictly speaking, this isn’t a highbay but rather it is a linear trunking system which can be used to attach luminaires. We chose this one because it is available as an IP54 chemically resistant version.
The LED gear tray is made of powder coated extruded aluminium and the seals and end caps are also oil resistant. The complete luminaire is the same width, 67 mm, as the trunking and can thus be mounted individually or almost continuously along the trunking.
It is supplied in lengths of 1m or 1.5m with single or twin LED boards. These range from 32W and emitting 5,130 lm to 100W emitting 16,423 lm. The standard colour temperature is 4000K with a CRI>80. 6500K and other CCTs are also available.
The pmma diffuser is available with a single, wide beam light distribution.
Sammode has a long history of making luminaires for harsh environments. The Barents is ideal for cold stores down to -40C (and up to +25C). It is available in a standard length of 1.85m and is 133mm diameter. The tubular body is made of co-extruded polycarbonate and pmma. End caps are 304L stainless steel. It has a high degree of impact resistance, IK10.
The Barents is rated at 125W and emits 13,700 lm at 5000K with a CRI>80. The single beam spread offered is 64 x 125 degrees so it is most suited for high, narrow areas such as cold store racking areas.
You can also use it in chill food areas where its IP69K rating means that it be cleaned with high pressure jets. The seamless body means that there is only a very small gasketed end where water could enter.
This is another trunking system intended for harsh environments to which you can attach its own dedicated luminaires. The Protected versions are 1.5m long, IP64 and operate from -35 up to 50C. All have a CRI >80.
The diffusers are pmma and offered in three beam widths from broad to extremely narrow. One aspect that is different from others is that it is offered as a tunable white, high output, medium output and an Eco version.
Typically, the output ranges from 8,180lm at 49W to 14,000lm at 86W.
Mirona Fit LED
The high temperature Mirona modular highbay operates from -30C up to 70C. The die-cast aluminium body is IP65, with an impact resistance of IK08.
The range is from 62W 10,700lm to 240W 40,000lm by combining one to six LED modules. All are 4000K and have a CRI >80.
The body has a large number of cooling fins and slots and the gear is mounted centrally so it remains cool and unaffected by the heat from the LEDs.
There are three beam widths available all with a glare rating of UGR <22.
Trilux say that the Mirona is also suitable where the surface temperature of the luminaire has to be kept below a certain value as described in IEC 60364-4-42.
Strictly speaking, this isn’t a highbay but the Amphibia is so well suited to harsh chemical environments that I had to include it.
A novel feature is that the body and cover lens are made of the same material so there are never any issues with different rates of expansion as the luminaire heats up and cools down. The join between the two sections is angled at 15 degrees so drips cannot collect on the lip and means that none spills on to the lens. Neither are there any fixing clips joining the two halves.
But what I like best is that the datasheet has a two-page table devoted to what chemical atmospheres the Amphibia will resist. It ranges from Acetic acid to Xylene! It even includes the percentage concentrations. The Amphibia can be supplied in three different clear materials so you can choose the model best suited to the chemicals in the atmosphere.
Three beam widths plus a wall wash are available. Light output is 3,000 – 10,000lm and available in 3000K, 4000K and 6500K, all with a CRI>80.