LED retrofitting: Approaches to upgrading industrial lighting.

Bringing an outdated lighting system up to the latest standards and switching from fluorescent tubes to LEDs requires a well-planned approach. The reasons for modernisation are usually reduced light quality due to outdated light sources, the withdrawal of the obsolete light source from the market as part of a phase-out, or a company’s own efforts to save energy. Switching to LED improves lighting quality and enhances user comfort. Professional luminaire refurbishment also makes it possible to preserve historic or unique luminaires. Below, we outline a range of options for LED retrofitting in industrial and warehouse lighting.

Assessing the current situation and clarifying requirements.

The first step is to take a close look at the existing system and clarify fundamental questions about the environment and the requirements of the lighting system: Have the lighting requirements for the area changed or not? What is the condition of the current installation and luminaires? Are there any changes to standards that need to be considered? What requirements will be placed on the system in future?

If the products are still in good condition and all standard-related and photometric requirements are unchanged, options such as retrofit kits or LED tubes may be considered. If luminaires with VDE/ENEC marking are needed, a detailed examination of the intended solution is necessary. A detailed assessment and risk analysis must be conducted before a final decision can be made.

Consider the legal situation.

Regardless of the approach chosen, the legal situation must always be considered. Depending on the solution, the obligations of the operator and the retrofitter differ considerably. In all cases, the person responsible must conduct a risk assessment of the retrofit.

LED tubes

LED tubes are used as a replacement for conventional fluorescent tubes and are managed in an equivalent way. But please note there is a difference between retrofit lamps and conversion lamps. Whilst with retrofit lamps only the light source and the starter are swapped or replaced by a current bridge, with conversion lamps the internal components of the luminaire are changed and rewired. This makes the legal situation more complex than with retrofit lamps.

Advantages of retrofit lamps

Familiar handling

With standard sockets and a current bridge, the process is like replacing fluorescent tubes and starters.

Lamps freely available for purchase

A wide range of lamps is available on the market; as a customer, you are not tied to a single supplier. However, there are correspondingly significant differences in quality within the market for LED tubes.

Disadvantages of retrofit lamps

Lighting characteristics

LED tubes have different light distribution curves to traditional fluorescent tubes. This affects the lighting characteristics achieved.

Limitations on technical specifications

It is not always possible to use LED tubes: emergency lighting or ENEC certification require separate consideration.

NORKA offers FIT luminaires which, when used in combination with approved lamps, are VDE and ENEC certified.

Like the ‘refurbishment’ process familiar in the consumer sector, it is also possible to fully refurbish luminaires and convert them to LED. The luminaires are cleaned, evaluated, and serviced by the manufacturer; where necessary, they are fitted with new seals and membranes and equipped with LEDs and the proper ballast.

Luminaire refurbishment by the manufacturer can be particularly beneficial for very high-quality, durable housings and larger projects. Often, these luminaires are customised designs that were already tailored to the customer’s requirements during their first life cycle, and replacing or developing them from scratch would entail significant financial costs.

Advantages of the 1:1 exchange

Existing installation stays in place.

Both mounting points and wiring can be kept. This reduces installation costs.

Suitable for emergency lighting, high IP ratings and in EX zones.

Specific technical requirements, such as a high IP rating, ATEX certification or operation as an emergency light, can usually be met at once by using new luminaires.

Latest technical innovations integrated.

New purchases incorporate the latest innovations, such as the interchangeability of LEDs – for example, with easy eXchange – or a DALI driver.

Disadvantages of a 1:1 replacement

Limited design flexibility.

As the existing installation points are kept, design flexibility is limited, and new space utilisation requirements may sometimes not be met.

Advantages of a redesign

Design freedoy

A redesign and procurement process offers the full range of creative and planning freedoms. Adaptation to new usage concepts or regulatory requirements is possible.

Integrated modern technology

The use of new luminaires allows for the incorporation of innovations, including integration into building management systems – for example, using DALI – or the use of luminaires with replaceable LEDs such as easy eXchange.

Disadvantages of a new design

Higher costs

Installing a new system can sometimes involve higher costs than refurbishing an existing one. However, the comparison depends heavily on the type of refurbishment chosen. When using RENOKITs, costs are expected to be 40–50 % lower than for a completely new luminaire. These savings relate to the procurement costs.

Premature end to valuable resources

High-quality housings made of aluminium, stainless steel or plastic can sometimes be used for decades, whilst the electronics inside reach the end of their service life sooner. When replacing luminaires rather than refurbishing them, fully functional housings are removed and usually sent for recycling, even though they are still usable.