P08428 LED Lighting Technologies for a Sustainable Entrepreneurial Venture

1. P08428 LED Lighting Technologies for a Sustainable Entrepreneurial Venture Team Members Sponsor: RIT Facilities Management Services

2. Agenda • Project Description (Shawn) • Design Concept (Taylor) • Reflector Design (David) • LED’s (Arthur) • Power Conditioning (Arthur) • Circuit Design (Phil) • PC Board Design (Phil) • Thermal Analysis (Taylor) • Economic Analysis (Christine) • Sustainability (Christine) • Remaining Improvements and Tasks (Shawn) • Questions

3. Project Description Create a new walkway lighting system with the use of LEDs Primary market is RIT Facilities Management Services Current annual cost to maintain and power 125 residential lights: $10,020

4. Design Concept (Metric #9, 11, 18, 20, 21 & 24) • Replaces internal components of existing fixture housing with LED lighting kit. • Use light weight material to comply with EPA regulations.

5. 5 board model (Metric # 6, 12, 13 & 14) • 5 boards are directed in 55, 67 and zero degree increments to displace the light to where it is needed.

6. Reflector design (Metric # 6, 12, 13, 14 & 20) • An elliptical reflector will maximize the light output. • An iterative linear approximation is shown to be used with CNC machining.

7. Light Distribution (Metrics 6, 12, 13, 14) • TracePro output shows that reflectors in previous slide would provide an acceptable light distribution. • Plot shows a minimum of 0.5 foot-candle over entire area. • Plot assumes three fixtures spaced 80’ apart.

8. Lens Testing (Metrics 12,13,14) • Photometry testing of Avago collimating lenses shows that the 15° do not conform to manufacturer’s specification sheet. • 30° collimator shows a close match to manufacturer’s data sheet. • Difference in lens light distribution explains failure of Alpha prototype.

9. LEDs (Metric # 2, 3, 7, 8, 12 – 17, 25, 26, 27 & 28) • Cree LEDs were used to provide a higher temperature resistance with a maximum junction temperature of 15o°F. • The LEDs have a CRI of 75. • The color temperature meets specifications of 4100K. • Long life time of 50,000 reduces amount of required replacements. • The power usage is 1.4watts each.

10. Power conditioning (Metric # 2, 3, 7, 17 & 21) • New transformer accommodates 120, 208 & 240VAC input. • Readily available at lower cost. • Outputs 24VAC.

11. Circuit design (Metric # 1, 2, 3, 7, 20 & 23) • Designed to meet applicable codes. • RC filter to limit ripple. • Use of common parts to keep manufacturing costs low. • Use of ROHS compliant components. • Reflowed at proper temperatures to maintain good mechanical bond.

12. PC board design (Metric # 7, 9, 10, 20, 26 & 27) • Added keyhole slots to improve contact between PCB and back plate while retaining easy replacement of boards. • Boards were designed to be interchangeable.

13. Thermal Analysis (Metric # 25, 26 & 27) • Each board was analyzed to determine the size and spacing requirements of the board. • Aluminum was laminated to the back of the boards to improve heat transfer.

14. Thermal Analysis of 5 board model (Metric # 25, 26 & 27) • More surface area was added to the back plate to dissipate added heat. • Transformers were placed on their own plate to distribute heat evenly.

15. Economic Analysis (Metric # 17, 20, 21, 22, 29 & 30) Budget for prototypes Total of 3 prototypes: $1802.83 + shipping Initial prototype cost – one fixture Initial investment per kit: $576.80 Retrofit scenario – 125 fixtures Approximate sale price per fixture: $430 Total initial investment: $58,732 Annual savings: $8,049 Energy savings: $3,777 Labor and material savings: $4,600 Payback period: 7.3 years Rate of return: 13.7%

16. Sustainability (Metric # 4, 5, & 19)

17. Remaining improvements & tasks Install fixtures. LED lighting survey. More in-depth climate analysis. Light density and spread tests. Replacement time test. Retrofit testing of Beta Prototype.

18. Questions