Lightfair International 2011 Field Report

Semiconductor manufacturers are increasingly interested in the LED lighting market as it matures and profitability levels increase. LED makers are stepping up their production significantly by converting their chip facilities to 6-in., 8-in., and 12-in. wafers, which can achieve 70% to 80% cost reductions. This accelerated demand and increased production capacity brings vitality and interest to the market, as witnessed by Korean companies LG Innotek and Samsung, attending the show for the first time.

Solid-state light sources are separated into two categories: LED replacement lamps that fit into existing incandescent screw and pin sockets, which formed a $1 billion market in 2010, and LED luminaires, which was a $3.98 billion market in 2010. Both categories generally have advantages over legacy lighting products in terms of energy efficiency, longevity, directional light output, variety, versatility, durability, and compact size.

The replacements

Developments of interest in replacement lamps seem to be widespread. Following are some highlights seen on the show floor.

Acuity Brands announced its acculamp product line, the S-Series, which includes LED versions of PAR16, PAR20, PAR30, PAR38, MR16, and AR111 lamps in multiple color temperatures and various beam patterns.

Osram Sylvania introduced the ULTRA Professional series of four PAR- type lamps, which offer a CRI of 95 and an R9 color rating greater than 50.

Philips gets around the heat dissipation problem on its A19 replacement Endua LED bulb by extending the heat sink material up into the dome of the lamp. General Electric (GE) uses a similar technique.

Switch Lighting showed a 100W equivalent, neutral white, A19 incandescent lamp, whose bulb interior is filled with an inert fluid to passively convection-cool the array of LEDs.

New look luminaires

GE showed innovative optical design in a line of flat-panel, edge-lit LED fixtures, available as recessed ceiling troffers and suspended fixtures that distribute light evenly over the flat surface of the acrylic-like transparent panel using True Edge technology from Rambus, Inc. The LED light source bars-to-light guide coupling achieves up to 95% efficiency, and the light output can be delivered across the entire surface of the panel, or it can be focused in specific patterns across the panel.

Cree displayed its CR series of LED troffers, available in three models, which offer 90 CRI and 90 to 110 lumens per watt. The LED array is aimed upward into a mixing chamber for low-brightness, uniform light distribution. Two-step dimming to 50% is standard, and zero to 10V dimming to 5% is optional.

The Juno Lighting Group Acculite Alari LED roadway and area luminaries feature field-rotatable optics and are available with 0V to 10V dimming or DALI control. The Finia Series serves medium mounting heights and flood lighting applications. The Acculux line of 3¼-in. round- and square-aperature LED downlights includes features that speed installation for contractors.

Philips’ Jump direct linear luminaire, for either LED or fluorescent light sources, features optics having holographic nanotechnology to provide precise batwing distribution. The fixture, which is available in a variety of patterns, colors, and mounting options, also integrates daylight harvesting sensors and Airwave wireless, battery-free solar and kinetically powered control to reduce energy consumption.

Kim Lighting offers the WARP9, a 100,000-hr rated lighting system that is available in 100W or 150W sizes. The Structural LED luminaire offers a variety of light distributions, and the driver has a 0V to 10V DC interface.

BetaLED showed its LEDway SLM and SLM IP-66 streetlights, which provide protection from ingress contamination. Both pole-mounted units can replace 70W to 250W HPS fixtures. The Essentia downlight for commercial and high-end residential applications features 4-, 6-, and 8-in. round and square apertures, with light outputs from 1,200 to 5,000 lumens.

Cool components

Along with developments in the LED chip, replacement lamp, and new luminaire arenas, components (such as modules, drivers, color, optics, cooling technologies, and dimming/control systems) showed much improvement. Following are some areas of interest that prompted a second look at this year’s Lightfair event.

Modules — A module typically integrates a driver, LED chip, lens, and thermal management components in form factors for popular lighting applications. For example, TE Connectivity (previously Tyco Electronics) showed off its Nevalo SSL system, which has optics with either internal reflection or reflectors, drivers with constant current output, dimming control capability and temperature monitoring.

Molex and Bridgelux introduced the Helion R 120V AC light module, which connects directly to an AC circuit, eliminating the need for a driver. Available in 1,200 and 2,000 lumen ratings, it can be dimmed to less than 5% output.

Cree’s LM4 module integrates driver electronics, optics, and primary thermal management for easy use.

Philip’s Fortimo module is available in four outputs, up to 8,000 lumens at 90 lpw, with multiple color temperatures and CRIs.

LedEngin offers the LuxiGen Platform, an integrated module system providing high flux density and directional light output, for one, four, 12, and 24 die emitters with interlocking glass lenses.

GE’s Infusion modules, which can be connected to a socket in the luminaire body with a simple twist-lock mechanism, are available in 1,000, 1,500, 2,000, and 3,000 lumen models, which currently are used by 10 fixture makers. GE is also working with a broad range of driver cooling system and control suppliers.

Luminous Devices showed the 6,500 lumen SoloLux module, developed for T-Opto, a Division of Toyota Tsusho America. It allows a field-upgradable solution for a 175W metal-halide fixture in an assembly plant environment.

Cooper Lighting developed a linear light production module, called the ALM 1.0, that uses multiple LEDs operating at a reduced power level to gain extended life. The module is used in 32 luminaires within the Ametrix, Corelite, Fail-Safe, Metalux, and Neo-Ray brands. The system provides performance equal to fluorescent lamps for recessed, surface, or direct-indirect general illumination and wall-washing applications.

Osram Sylvania announced three solid-state lighting products that are compliant with the EMerge Alliance standard for 24VDC power distribution in an occupied space of a commercial building. The new product line includes: the Exterior Light Engine, the HF2Chain module for signage or contoured applications, and the HF2Narrow Stick for creating a linear light source.

Drivers — These items are similar to the ballasts for arc discharge lamps and are expanding in function to provide applications such as power factor correction, wired or wireless control, and color sequencing, while supporting multiple chips. Many products offer universal voltage input, controllability from wired or wireless networks, and transient voltage protection for exterior roadway luminaires.

Phihong has outdoor-rated AC-DC drivers in full potted metal casings (IP66 listed) and are available in constant current or constant voltage models.

Maxim Integrated Products has a driver that shapes the input current to ensure flicker-free dimming operation with electronic transformers and cut-angle dimmers. This allows retrofit LED lamps to replace halogen MR16s without flicker or dropout problems.

Color — Variation in LED color production continues to differentiate manufacturers as they strive to enhance performance. By moving the phosphor away from the surface of the chip, remote phosphor designs claim a 10% to 30% boost in efficiency.

Philips’ Luxeon A is the first single-emitter that is part of the company’s “Freedom from Binning” concept, joining the multi-emitter Luxeon S (nine LED dies) in the program. A precise thickness of the ceramic phosphor allows for an accurate prediction of a specific correlated color temperature. As a result, each die falls within one 3-step Mac Adam ellipse space at actual operating conditions. Although data sheets typically present data for LEDs at 25°C, the actual operating temperature is closer to 85°C and sometimes higher. Thus, each die is tested at 85°C, so the color point and performance numbers are known. Cree and Intermatix also use blue LEDs with a specific wavelength range and proprietary phosphor technology.

The Intermatix ChromaLit system has a phosphor composite precisely layered onto a substrate, separated from the blue LED, and the phosphor component can be made in any shape and color.

Renaissance Lighting, now part of Acuity Brands, has nanotechnology patents related to white light production and optical solutions. Other makers boasting similar color improvements are Osram Optiled and the Lighting Science Group.

For specialized applications, Everbrite Lighting introduced a color changing light system called the MedLux cove lighting system, for both MRI and non-MRI applications, that does not emit radio frequencies, thus eliminating the potential for image-degrading artifacts.

Dimming and control — Combine LEDs fast response and smooth dimming capability with sensors and control, and they can deliver the right amount of light continuously. Dimming an LED with digital controls reduces the operating temperature, thereby extending the useful life of components and the driver electronics. In addition, it saves energy.

Integrated within four LED ceiling luminaire products by Lithonia Lighting and a downlight series by Gotham, is a control system called nLIGHT that communicates via Cat. 5 cabling to occupancy sensors, photocells, and wall controls. Over time, the lumen management system saves energy while allowing the light level to remain constant. Continuous dimming and switching is done without a relay, separate dimming wires, or commissioning, as was seen in a demo room at the Acuity booth.

Schneider Electric introduced its EM Lighting Control System, which combines individual branch circuit remote control and metering functions in a single lighting panelboard. The panelboards have four different levels of size, construction, and capabilities. The 2000 level uses the fast-Ethernet protocol, and the 3000 level provides Web-enabled control.

Cooper Controls displayed its Venergy Advanced Metering System that collects time-differentiated energy use data from advanced meters using a communications network. Information is reviewed via PCs, an iPhone, an iPad, and other tablets.

Lutron Electronics showed its new generation EcoSystem solutions for commercial lighting control, which is DALI-based, using a 2-wire bus circuit or wireless communications to integrate daylight sensors, occupancy sensors and ballasts. Designed to save unnecessary energy use, the system can be expanded to any control need, including the operation of shades. The Diva CL dimmer can serve incandescent/halogen, compact fluorescent, and most LED replacement lamps. Multiple types of lamps can be mixed on a single dimmer as well.

Leviton offers the LevNet RF wall switch, which can replace a traditional single-pole switch to provide battery-less, wireless control capability, and is especially useful with other sensors, receivers, and transmitters devices for retrofitting an existing hotel facility to achieve energy savings. The GreenMax Relay control system features a 25,000A short-circuit rating, daylight harvesting, and smart metering capability. Programming and monitor is done via a portable handheld unit.

The EnOcean consortium promoting battery-less, wireless control systems is assembling a community of partners using the building area network (BAN) wireless standard and has partnerships with all the major protocols, including BACnet, LonWorks, and DALI. It also has established TCP/IP
interoperability with end-devices, allowing monitoring and control from any Web-enabled device, making the feature useful for smaller buildings lacking a building automation system.

Hubble Lighting has its wiHBB Wireless Distributed Lighting Control System, a peer-to-peer, self-organizing, and self-healing network of fixtures, occupancy sensors, daylight harvesting sensors, and switch stations. Applications include high-bay industrial areas and numerous other settings. The Zone5 Daylight Harvesting system serves four variable lighting zones.

Panasonic Electric Works of America showed its Full-2Way lighting control system that uses a topology-free, polarity-neutral wiring scheme to connect switches, sensors, time clocks, and other panel components. The system can be used for daylight harvesting, occupancy sensing load shedding, and demand control.

Redwood Systems has new power delivery capabilities which allows a single “engine” appliance to drive up to 64 20W-rated LED luminaires via an 18-gauge, low-voltage wiring system. The new design permits the replacement of the AC input modules with modules that accept DC voltage, such as a solar or battery feed. The engine contains a processor board that provides Ethernet communications to the wiring system (also a data network) and controls the power and communications to the luminaires and their adapters (sensors).

Daintree Networks offers the ControlScope wireless lighting control platform for new or remodeled office areas, using ZigBee mesh architecture for communications.

Encelium Technology introduced the Polaris 3D lighting control software for its Energy Control System, which features 3-D building views and ease of navigation.

Osram Sylvania introduced the Optotronic OT Dim LED control interface for dimming down to 0% via pulse-width modulation. In addition, its Elogic wireless dimming control, for fluorescent ballasts and LED power supply devices fits within the EnOcean Alliance standard for battery-free, low-power radio transmission in a building.