complete report jatin
TRANSCRIPT
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Under the Guidanceof
Mr Aditya Tyagi amp Mr Manish MohanSrRampD Engineers
Compiled By Name Jatin Sharma
Roll No 277264
Branch ECE (Eve)
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CERTIFICATE
TO WHOM IT MAY CONCERN
This is to certify that Master Jatin Sharma Pursuing Diploma in Electronics and
communication from Guru Nanak Dev Co-ed Polytechnic under Delhi technical
university Delhi has been under Industrial training from 10th
July to 22nd
August 2009
under my guidance During this tenure he has worked on testing and working of various
product from our range and successfully completed them to the best of his abilities
His conduct has been good during this tenure
We wish him good luck for his future Assignments
Jatin Sharma
Roll No 277264
CE (Eve) For Instapower
(Authorized signatory)
Mr Arun Bhatia
VP Business Development
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Table Of Contents
Prefacehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip i
Acknowledgementhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip ii
Company profilehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellipiii
Chapter 1 Introduction helliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip1
Chapter 2 New Technologyhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip3
Chapter 3 Lighting factshelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip11
Chapter 4 How to produce LEDshelliphelliphelliphelliphelliphelliphelliphelliphellip16
Chapter 5 Market potentialhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip19
Chapter 6 Case studieshelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip22
Chapter 7 Assignment Undertakenhelliphelliphelliphelliphelliphelliphelliphellip25
Appendix Photo galleryhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip35
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TRAINING REPORT ON LED LIGHTING
PREFACE
The industrial training gives students an opportunity to learn the practical
experience This provides him a wisdom of applying his theoretical knowledge into
practical fields I got this opportunity to enhance my practical experience at Instapower
Ltd Gurgaon
Energy conservation has become the hottest topic these days So Government is
working on it and formed many organizations like Bureau of Energy Efficiency (BEE)
are working very dedicatedly This report explains the basics of the LED technology and
its application in Energy efficient lighting Comparative studies between conventional or
contemporaries like Incandescent bulbs CFL with LEDs light has been done and hence
the forthcoming potential market is observed
In total the motto of the report is ldquoPower Saved is Power Earnedrdquo
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TRAINING REPORT ON LED LIGHTING
ACKNOWLEDGEMENT
This industrial training has been carried out due to the kind support from Mr
Himanshu Rai Vaish Managing Director Instapower Ltd Gurgaon Haryana I am
grateful to him for giving me an opportunity to do my six weeks summer training in his
Organization
I take this privilege to express my gratitude and sincere appreciation to
Mr Arun Bhatia Sr V P Business Development my guides Mr Aditya Tyagi Sr
Engineer RampD and Mr Manish Mohan Sr Engineer RampD for their extremely
intruding valuable guidance constant encouragement and personal involvement and
gracious relationship that has been of illimitable significance in shaping the quality of
work
I would like to thank Mr Rajdeep Pant Project Engineer Mr Zia-Ul-
Hassan Technical Support Engineer and other RampD Engineers of the organization for
their knowledgeable support and constant guidance during the training Also I convey
my gratitude to complete Instapower team who helped me in gaining this valuable
experience during the past six weeks
Last but not the least I would like to thank my parents and lecturers for their
valuable support during the training at this prestigious organization
Jatin Sharma
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TRAINING REPORT ON LED LIGHTING
COMPANY PROFILE
Instapower is a known name in the field of power electronics and has expertise in
the field of designing and manufacturing world class products It has been promoted byan alumnus of Indiarsquos premier institute Indian Institute of Technology Delhi It is anISO 9001 TUV (Germany) certified organization and has been in the field of power
electronics for nearly two decades In the past 5 years it has diversified into the area of
Energy Efficient Lighting Solutions using T5 Tube lights and LEDs The company has
over years developed new and innovative products and there has been constant endeavorto improve the quality of the products The company achieved an average growth rate of
100 per year in the last 5 years and is now poised for a steep growth
Instapower is the only organization in India which has such a diverse range of Led
Lighting and Fluorescent Tube light (Insta T5) products under one roof It has developed
the technology for LED-based system after investing many man-years in RampD masteringthe technology electronics and optics Instapower and its founder have filed more than
10 patents in India and abroad in the area of LED lighting and energy efficiency
Instapower has been recognized as RampD House by DSIR (Department forIndustrial Research Govt of India ) and also listed as an ESCO organization by the
Bureau of Energy Efficiency (BEE) Instapower is amongst the select few pioneers in
India who have propagated the LED technology
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TRAINING REPORT ON LED LIGHTING
Chapter 1 INTRODUCTION
We all know Power is a concurrent subject It is not just in India but the entireworld that has failed to make up for the shortage of power With energy prices on the rise
and natural resources receding it has become more important to conserve power for the brighter life of our future generation Small steps at the individual level can really changethe way we utilize electricity at homes or even outside A good supply of light does notnecessarily mean the consumption of a great deal of electricity If the right lamp isselected for the right type of function it is possible to save electricity
Unlike the CFLs LEDs can illuminate your houses as well as streets and even theoutdoors replacing the HIDs at a fraction of cost Until recently LEDs were limited tosingle-bulb use in applications such as instrument panels electronics and pen lights andmore recently strings of indoor and outdoor Christmas lights but now these small bulbsare ready to take the place of the established technologies for the better of the human
beings
Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025 the world would use 120 GW less electricity saving $100 billion a year andcutting the carbon-dioxide emissions from power plants by 350 Megatons annually
Innovations in photonics and solid state lighting will lead to trillions of dollars incost savings along with a massive reduction in the amount of energy required to lighthomes and businesses around the globe the researchers forecast In addition to theenvironmental and cost benefits of LEDs the technology is expected to enable a widerange of advances in areas as diverse as healthcare transportation systems digitaldisplays and computer networking
To bring all these things into reality there is urgent need to
a To develop mass level production to decrease cost b To adopt new technologies to reduce production costc In many energy conscious states government should enforce LED bulbs for street
lighting and other public areas to bring savings to bloated energy billsd Need more RampD efforts towards nano techlogy crystal technology used for LED
lighting
As per study or survey carried out in this report I am sure thatLED is surely a drive towards green earthhellip
So GO GREEN BY ADOPTING LEDs
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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TRAINING REPORT ON LED LIGHTING
Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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CERTIFICATE
TO WHOM IT MAY CONCERN
This is to certify that Master Jatin Sharma Pursuing Diploma in Electronics and
communication from Guru Nanak Dev Co-ed Polytechnic under Delhi technical
university Delhi has been under Industrial training from 10th
July to 22nd
August 2009
under my guidance During this tenure he has worked on testing and working of various
product from our range and successfully completed them to the best of his abilities
His conduct has been good during this tenure
We wish him good luck for his future Assignments
Jatin Sharma
Roll No 277264
CE (Eve) For Instapower
(Authorized signatory)
Mr Arun Bhatia
VP Business Development
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Table Of Contents
Prefacehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip i
Acknowledgementhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip ii
Company profilehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellipiii
Chapter 1 Introduction helliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip1
Chapter 2 New Technologyhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip3
Chapter 3 Lighting factshelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip11
Chapter 4 How to produce LEDshelliphelliphelliphelliphelliphelliphelliphelliphellip16
Chapter 5 Market potentialhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip19
Chapter 6 Case studieshelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip22
Chapter 7 Assignment Undertakenhelliphelliphelliphelliphelliphelliphelliphellip25
Appendix Photo galleryhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip35
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TRAINING REPORT ON LED LIGHTING
PREFACE
The industrial training gives students an opportunity to learn the practical
experience This provides him a wisdom of applying his theoretical knowledge into
practical fields I got this opportunity to enhance my practical experience at Instapower
Ltd Gurgaon
Energy conservation has become the hottest topic these days So Government is
working on it and formed many organizations like Bureau of Energy Efficiency (BEE)
are working very dedicatedly This report explains the basics of the LED technology and
its application in Energy efficient lighting Comparative studies between conventional or
contemporaries like Incandescent bulbs CFL with LEDs light has been done and hence
the forthcoming potential market is observed
In total the motto of the report is ldquoPower Saved is Power Earnedrdquo
GND POLYTECHNIC ROHINI NEW DELHI i
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TRAINING REPORT ON LED LIGHTING
ACKNOWLEDGEMENT
This industrial training has been carried out due to the kind support from Mr
Himanshu Rai Vaish Managing Director Instapower Ltd Gurgaon Haryana I am
grateful to him for giving me an opportunity to do my six weeks summer training in his
Organization
I take this privilege to express my gratitude and sincere appreciation to
Mr Arun Bhatia Sr V P Business Development my guides Mr Aditya Tyagi Sr
Engineer RampD and Mr Manish Mohan Sr Engineer RampD for their extremely
intruding valuable guidance constant encouragement and personal involvement and
gracious relationship that has been of illimitable significance in shaping the quality of
work
I would like to thank Mr Rajdeep Pant Project Engineer Mr Zia-Ul-
Hassan Technical Support Engineer and other RampD Engineers of the organization for
their knowledgeable support and constant guidance during the training Also I convey
my gratitude to complete Instapower team who helped me in gaining this valuable
experience during the past six weeks
Last but not the least I would like to thank my parents and lecturers for their
valuable support during the training at this prestigious organization
Jatin Sharma
GND POLYTECHNIC ROHINI NEW DELHI ii
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TRAINING REPORT ON LED LIGHTING
COMPANY PROFILE
Instapower is a known name in the field of power electronics and has expertise in
the field of designing and manufacturing world class products It has been promoted byan alumnus of Indiarsquos premier institute Indian Institute of Technology Delhi It is anISO 9001 TUV (Germany) certified organization and has been in the field of power
electronics for nearly two decades In the past 5 years it has diversified into the area of
Energy Efficient Lighting Solutions using T5 Tube lights and LEDs The company has
over years developed new and innovative products and there has been constant endeavorto improve the quality of the products The company achieved an average growth rate of
100 per year in the last 5 years and is now poised for a steep growth
Instapower is the only organization in India which has such a diverse range of Led
Lighting and Fluorescent Tube light (Insta T5) products under one roof It has developed
the technology for LED-based system after investing many man-years in RampD masteringthe technology electronics and optics Instapower and its founder have filed more than
10 patents in India and abroad in the area of LED lighting and energy efficiency
Instapower has been recognized as RampD House by DSIR (Department forIndustrial Research Govt of India ) and also listed as an ESCO organization by the
Bureau of Energy Efficiency (BEE) Instapower is amongst the select few pioneers in
India who have propagated the LED technology
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TRAINING REPORT ON LED LIGHTING
Chapter 1 INTRODUCTION
We all know Power is a concurrent subject It is not just in India but the entireworld that has failed to make up for the shortage of power With energy prices on the rise
and natural resources receding it has become more important to conserve power for the brighter life of our future generation Small steps at the individual level can really changethe way we utilize electricity at homes or even outside A good supply of light does notnecessarily mean the consumption of a great deal of electricity If the right lamp isselected for the right type of function it is possible to save electricity
Unlike the CFLs LEDs can illuminate your houses as well as streets and even theoutdoors replacing the HIDs at a fraction of cost Until recently LEDs were limited tosingle-bulb use in applications such as instrument panels electronics and pen lights andmore recently strings of indoor and outdoor Christmas lights but now these small bulbsare ready to take the place of the established technologies for the better of the human
beings
Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025 the world would use 120 GW less electricity saving $100 billion a year andcutting the carbon-dioxide emissions from power plants by 350 Megatons annually
Innovations in photonics and solid state lighting will lead to trillions of dollars incost savings along with a massive reduction in the amount of energy required to lighthomes and businesses around the globe the researchers forecast In addition to theenvironmental and cost benefits of LEDs the technology is expected to enable a widerange of advances in areas as diverse as healthcare transportation systems digitaldisplays and computer networking
To bring all these things into reality there is urgent need to
a To develop mass level production to decrease cost b To adopt new technologies to reduce production costc In many energy conscious states government should enforce LED bulbs for street
lighting and other public areas to bring savings to bloated energy billsd Need more RampD efforts towards nano techlogy crystal technology used for LED
lighting
As per study or survey carried out in this report I am sure thatLED is surely a drive towards green earthhellip
So GO GREEN BY ADOPTING LEDs
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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Table Of Contents
Prefacehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip i
Acknowledgementhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip ii
Company profilehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellipiii
Chapter 1 Introduction helliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip1
Chapter 2 New Technologyhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip3
Chapter 3 Lighting factshelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip11
Chapter 4 How to produce LEDshelliphelliphelliphelliphelliphelliphelliphelliphellip16
Chapter 5 Market potentialhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip19
Chapter 6 Case studieshelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip22
Chapter 7 Assignment Undertakenhelliphelliphelliphelliphelliphelliphelliphellip25
Appendix Photo galleryhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip35
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TRAINING REPORT ON LED LIGHTING
PREFACE
The industrial training gives students an opportunity to learn the practical
experience This provides him a wisdom of applying his theoretical knowledge into
practical fields I got this opportunity to enhance my practical experience at Instapower
Ltd Gurgaon
Energy conservation has become the hottest topic these days So Government is
working on it and formed many organizations like Bureau of Energy Efficiency (BEE)
are working very dedicatedly This report explains the basics of the LED technology and
its application in Energy efficient lighting Comparative studies between conventional or
contemporaries like Incandescent bulbs CFL with LEDs light has been done and hence
the forthcoming potential market is observed
In total the motto of the report is ldquoPower Saved is Power Earnedrdquo
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TRAINING REPORT ON LED LIGHTING
ACKNOWLEDGEMENT
This industrial training has been carried out due to the kind support from Mr
Himanshu Rai Vaish Managing Director Instapower Ltd Gurgaon Haryana I am
grateful to him for giving me an opportunity to do my six weeks summer training in his
Organization
I take this privilege to express my gratitude and sincere appreciation to
Mr Arun Bhatia Sr V P Business Development my guides Mr Aditya Tyagi Sr
Engineer RampD and Mr Manish Mohan Sr Engineer RampD for their extremely
intruding valuable guidance constant encouragement and personal involvement and
gracious relationship that has been of illimitable significance in shaping the quality of
work
I would like to thank Mr Rajdeep Pant Project Engineer Mr Zia-Ul-
Hassan Technical Support Engineer and other RampD Engineers of the organization for
their knowledgeable support and constant guidance during the training Also I convey
my gratitude to complete Instapower team who helped me in gaining this valuable
experience during the past six weeks
Last but not the least I would like to thank my parents and lecturers for their
valuable support during the training at this prestigious organization
Jatin Sharma
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TRAINING REPORT ON LED LIGHTING
COMPANY PROFILE
Instapower is a known name in the field of power electronics and has expertise in
the field of designing and manufacturing world class products It has been promoted byan alumnus of Indiarsquos premier institute Indian Institute of Technology Delhi It is anISO 9001 TUV (Germany) certified organization and has been in the field of power
electronics for nearly two decades In the past 5 years it has diversified into the area of
Energy Efficient Lighting Solutions using T5 Tube lights and LEDs The company has
over years developed new and innovative products and there has been constant endeavorto improve the quality of the products The company achieved an average growth rate of
100 per year in the last 5 years and is now poised for a steep growth
Instapower is the only organization in India which has such a diverse range of Led
Lighting and Fluorescent Tube light (Insta T5) products under one roof It has developed
the technology for LED-based system after investing many man-years in RampD masteringthe technology electronics and optics Instapower and its founder have filed more than
10 patents in India and abroad in the area of LED lighting and energy efficiency
Instapower has been recognized as RampD House by DSIR (Department forIndustrial Research Govt of India ) and also listed as an ESCO organization by the
Bureau of Energy Efficiency (BEE) Instapower is amongst the select few pioneers in
India who have propagated the LED technology
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TRAINING REPORT ON LED LIGHTING
Chapter 1 INTRODUCTION
We all know Power is a concurrent subject It is not just in India but the entireworld that has failed to make up for the shortage of power With energy prices on the rise
and natural resources receding it has become more important to conserve power for the brighter life of our future generation Small steps at the individual level can really changethe way we utilize electricity at homes or even outside A good supply of light does notnecessarily mean the consumption of a great deal of electricity If the right lamp isselected for the right type of function it is possible to save electricity
Unlike the CFLs LEDs can illuminate your houses as well as streets and even theoutdoors replacing the HIDs at a fraction of cost Until recently LEDs were limited tosingle-bulb use in applications such as instrument panels electronics and pen lights andmore recently strings of indoor and outdoor Christmas lights but now these small bulbsare ready to take the place of the established technologies for the better of the human
beings
Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025 the world would use 120 GW less electricity saving $100 billion a year andcutting the carbon-dioxide emissions from power plants by 350 Megatons annually
Innovations in photonics and solid state lighting will lead to trillions of dollars incost savings along with a massive reduction in the amount of energy required to lighthomes and businesses around the globe the researchers forecast In addition to theenvironmental and cost benefits of LEDs the technology is expected to enable a widerange of advances in areas as diverse as healthcare transportation systems digitaldisplays and computer networking
To bring all these things into reality there is urgent need to
a To develop mass level production to decrease cost b To adopt new technologies to reduce production costc In many energy conscious states government should enforce LED bulbs for street
lighting and other public areas to bring savings to bloated energy billsd Need more RampD efforts towards nano techlogy crystal technology used for LED
lighting
As per study or survey carried out in this report I am sure thatLED is surely a drive towards green earthhellip
So GO GREEN BY ADOPTING LEDs
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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TRAINING REPORT ON LED LIGHTING
Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
GND POLYTECHNIC ROHINI NEW DELHI 23
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
PREFACE
The industrial training gives students an opportunity to learn the practical
experience This provides him a wisdom of applying his theoretical knowledge into
practical fields I got this opportunity to enhance my practical experience at Instapower
Ltd Gurgaon
Energy conservation has become the hottest topic these days So Government is
working on it and formed many organizations like Bureau of Energy Efficiency (BEE)
are working very dedicatedly This report explains the basics of the LED technology and
its application in Energy efficient lighting Comparative studies between conventional or
contemporaries like Incandescent bulbs CFL with LEDs light has been done and hence
the forthcoming potential market is observed
In total the motto of the report is ldquoPower Saved is Power Earnedrdquo
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TRAINING REPORT ON LED LIGHTING
ACKNOWLEDGEMENT
This industrial training has been carried out due to the kind support from Mr
Himanshu Rai Vaish Managing Director Instapower Ltd Gurgaon Haryana I am
grateful to him for giving me an opportunity to do my six weeks summer training in his
Organization
I take this privilege to express my gratitude and sincere appreciation to
Mr Arun Bhatia Sr V P Business Development my guides Mr Aditya Tyagi Sr
Engineer RampD and Mr Manish Mohan Sr Engineer RampD for their extremely
intruding valuable guidance constant encouragement and personal involvement and
gracious relationship that has been of illimitable significance in shaping the quality of
work
I would like to thank Mr Rajdeep Pant Project Engineer Mr Zia-Ul-
Hassan Technical Support Engineer and other RampD Engineers of the organization for
their knowledgeable support and constant guidance during the training Also I convey
my gratitude to complete Instapower team who helped me in gaining this valuable
experience during the past six weeks
Last but not the least I would like to thank my parents and lecturers for their
valuable support during the training at this prestigious organization
Jatin Sharma
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TRAINING REPORT ON LED LIGHTING
COMPANY PROFILE
Instapower is a known name in the field of power electronics and has expertise in
the field of designing and manufacturing world class products It has been promoted byan alumnus of Indiarsquos premier institute Indian Institute of Technology Delhi It is anISO 9001 TUV (Germany) certified organization and has been in the field of power
electronics for nearly two decades In the past 5 years it has diversified into the area of
Energy Efficient Lighting Solutions using T5 Tube lights and LEDs The company has
over years developed new and innovative products and there has been constant endeavorto improve the quality of the products The company achieved an average growth rate of
100 per year in the last 5 years and is now poised for a steep growth
Instapower is the only organization in India which has such a diverse range of Led
Lighting and Fluorescent Tube light (Insta T5) products under one roof It has developed
the technology for LED-based system after investing many man-years in RampD masteringthe technology electronics and optics Instapower and its founder have filed more than
10 patents in India and abroad in the area of LED lighting and energy efficiency
Instapower has been recognized as RampD House by DSIR (Department forIndustrial Research Govt of India ) and also listed as an ESCO organization by the
Bureau of Energy Efficiency (BEE) Instapower is amongst the select few pioneers in
India who have propagated the LED technology
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TRAINING REPORT ON LED LIGHTING
Chapter 1 INTRODUCTION
We all know Power is a concurrent subject It is not just in India but the entireworld that has failed to make up for the shortage of power With energy prices on the rise
and natural resources receding it has become more important to conserve power for the brighter life of our future generation Small steps at the individual level can really changethe way we utilize electricity at homes or even outside A good supply of light does notnecessarily mean the consumption of a great deal of electricity If the right lamp isselected for the right type of function it is possible to save electricity
Unlike the CFLs LEDs can illuminate your houses as well as streets and even theoutdoors replacing the HIDs at a fraction of cost Until recently LEDs were limited tosingle-bulb use in applications such as instrument panels electronics and pen lights andmore recently strings of indoor and outdoor Christmas lights but now these small bulbsare ready to take the place of the established technologies for the better of the human
beings
Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025 the world would use 120 GW less electricity saving $100 billion a year andcutting the carbon-dioxide emissions from power plants by 350 Megatons annually
Innovations in photonics and solid state lighting will lead to trillions of dollars incost savings along with a massive reduction in the amount of energy required to lighthomes and businesses around the globe the researchers forecast In addition to theenvironmental and cost benefits of LEDs the technology is expected to enable a widerange of advances in areas as diverse as healthcare transportation systems digitaldisplays and computer networking
To bring all these things into reality there is urgent need to
a To develop mass level production to decrease cost b To adopt new technologies to reduce production costc In many energy conscious states government should enforce LED bulbs for street
lighting and other public areas to bring savings to bloated energy billsd Need more RampD efforts towards nano techlogy crystal technology used for LED
lighting
As per study or survey carried out in this report I am sure thatLED is surely a drive towards green earthhellip
So GO GREEN BY ADOPTING LEDs
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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TRAINING REPORT ON LED LIGHTING
Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
ACKNOWLEDGEMENT
This industrial training has been carried out due to the kind support from Mr
Himanshu Rai Vaish Managing Director Instapower Ltd Gurgaon Haryana I am
grateful to him for giving me an opportunity to do my six weeks summer training in his
Organization
I take this privilege to express my gratitude and sincere appreciation to
Mr Arun Bhatia Sr V P Business Development my guides Mr Aditya Tyagi Sr
Engineer RampD and Mr Manish Mohan Sr Engineer RampD for their extremely
intruding valuable guidance constant encouragement and personal involvement and
gracious relationship that has been of illimitable significance in shaping the quality of
work
I would like to thank Mr Rajdeep Pant Project Engineer Mr Zia-Ul-
Hassan Technical Support Engineer and other RampD Engineers of the organization for
their knowledgeable support and constant guidance during the training Also I convey
my gratitude to complete Instapower team who helped me in gaining this valuable
experience during the past six weeks
Last but not the least I would like to thank my parents and lecturers for their
valuable support during the training at this prestigious organization
Jatin Sharma
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TRAINING REPORT ON LED LIGHTING
COMPANY PROFILE
Instapower is a known name in the field of power electronics and has expertise in
the field of designing and manufacturing world class products It has been promoted byan alumnus of Indiarsquos premier institute Indian Institute of Technology Delhi It is anISO 9001 TUV (Germany) certified organization and has been in the field of power
electronics for nearly two decades In the past 5 years it has diversified into the area of
Energy Efficient Lighting Solutions using T5 Tube lights and LEDs The company has
over years developed new and innovative products and there has been constant endeavorto improve the quality of the products The company achieved an average growth rate of
100 per year in the last 5 years and is now poised for a steep growth
Instapower is the only organization in India which has such a diverse range of Led
Lighting and Fluorescent Tube light (Insta T5) products under one roof It has developed
the technology for LED-based system after investing many man-years in RampD masteringthe technology electronics and optics Instapower and its founder have filed more than
10 patents in India and abroad in the area of LED lighting and energy efficiency
Instapower has been recognized as RampD House by DSIR (Department forIndustrial Research Govt of India ) and also listed as an ESCO organization by the
Bureau of Energy Efficiency (BEE) Instapower is amongst the select few pioneers in
India who have propagated the LED technology
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TRAINING REPORT ON LED LIGHTING
Chapter 1 INTRODUCTION
We all know Power is a concurrent subject It is not just in India but the entireworld that has failed to make up for the shortage of power With energy prices on the rise
and natural resources receding it has become more important to conserve power for the brighter life of our future generation Small steps at the individual level can really changethe way we utilize electricity at homes or even outside A good supply of light does notnecessarily mean the consumption of a great deal of electricity If the right lamp isselected for the right type of function it is possible to save electricity
Unlike the CFLs LEDs can illuminate your houses as well as streets and even theoutdoors replacing the HIDs at a fraction of cost Until recently LEDs were limited tosingle-bulb use in applications such as instrument panels electronics and pen lights andmore recently strings of indoor and outdoor Christmas lights but now these small bulbsare ready to take the place of the established technologies for the better of the human
beings
Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025 the world would use 120 GW less electricity saving $100 billion a year andcutting the carbon-dioxide emissions from power plants by 350 Megatons annually
Innovations in photonics and solid state lighting will lead to trillions of dollars incost savings along with a massive reduction in the amount of energy required to lighthomes and businesses around the globe the researchers forecast In addition to theenvironmental and cost benefits of LEDs the technology is expected to enable a widerange of advances in areas as diverse as healthcare transportation systems digitaldisplays and computer networking
To bring all these things into reality there is urgent need to
a To develop mass level production to decrease cost b To adopt new technologies to reduce production costc In many energy conscious states government should enforce LED bulbs for street
lighting and other public areas to bring savings to bloated energy billsd Need more RampD efforts towards nano techlogy crystal technology used for LED
lighting
As per study or survey carried out in this report I am sure thatLED is surely a drive towards green earthhellip
So GO GREEN BY ADOPTING LEDs
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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TRAINING REPORT ON LED LIGHTING
Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
COMPANY PROFILE
Instapower is a known name in the field of power electronics and has expertise in
the field of designing and manufacturing world class products It has been promoted byan alumnus of Indiarsquos premier institute Indian Institute of Technology Delhi It is anISO 9001 TUV (Germany) certified organization and has been in the field of power
electronics for nearly two decades In the past 5 years it has diversified into the area of
Energy Efficient Lighting Solutions using T5 Tube lights and LEDs The company has
over years developed new and innovative products and there has been constant endeavorto improve the quality of the products The company achieved an average growth rate of
100 per year in the last 5 years and is now poised for a steep growth
Instapower is the only organization in India which has such a diverse range of Led
Lighting and Fluorescent Tube light (Insta T5) products under one roof It has developed
the technology for LED-based system after investing many man-years in RampD masteringthe technology electronics and optics Instapower and its founder have filed more than
10 patents in India and abroad in the area of LED lighting and energy efficiency
Instapower has been recognized as RampD House by DSIR (Department forIndustrial Research Govt of India ) and also listed as an ESCO organization by the
Bureau of Energy Efficiency (BEE) Instapower is amongst the select few pioneers in
India who have propagated the LED technology
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TRAINING REPORT ON LED LIGHTING
Chapter 1 INTRODUCTION
We all know Power is a concurrent subject It is not just in India but the entireworld that has failed to make up for the shortage of power With energy prices on the rise
and natural resources receding it has become more important to conserve power for the brighter life of our future generation Small steps at the individual level can really changethe way we utilize electricity at homes or even outside A good supply of light does notnecessarily mean the consumption of a great deal of electricity If the right lamp isselected for the right type of function it is possible to save electricity
Unlike the CFLs LEDs can illuminate your houses as well as streets and even theoutdoors replacing the HIDs at a fraction of cost Until recently LEDs were limited tosingle-bulb use in applications such as instrument panels electronics and pen lights andmore recently strings of indoor and outdoor Christmas lights but now these small bulbsare ready to take the place of the established technologies for the better of the human
beings
Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025 the world would use 120 GW less electricity saving $100 billion a year andcutting the carbon-dioxide emissions from power plants by 350 Megatons annually
Innovations in photonics and solid state lighting will lead to trillions of dollars incost savings along with a massive reduction in the amount of energy required to lighthomes and businesses around the globe the researchers forecast In addition to theenvironmental and cost benefits of LEDs the technology is expected to enable a widerange of advances in areas as diverse as healthcare transportation systems digitaldisplays and computer networking
To bring all these things into reality there is urgent need to
a To develop mass level production to decrease cost b To adopt new technologies to reduce production costc In many energy conscious states government should enforce LED bulbs for street
lighting and other public areas to bring savings to bloated energy billsd Need more RampD efforts towards nano techlogy crystal technology used for LED
lighting
As per study or survey carried out in this report I am sure thatLED is surely a drive towards green earthhellip
So GO GREEN BY ADOPTING LEDs
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Chapter 1 INTRODUCTION
We all know Power is a concurrent subject It is not just in India but the entireworld that has failed to make up for the shortage of power With energy prices on the rise
and natural resources receding it has become more important to conserve power for the brighter life of our future generation Small steps at the individual level can really changethe way we utilize electricity at homes or even outside A good supply of light does notnecessarily mean the consumption of a great deal of electricity If the right lamp isselected for the right type of function it is possible to save electricity
Unlike the CFLs LEDs can illuminate your houses as well as streets and even theoutdoors replacing the HIDs at a fraction of cost Until recently LEDs were limited tosingle-bulb use in applications such as instrument panels electronics and pen lights andmore recently strings of indoor and outdoor Christmas lights but now these small bulbsare ready to take the place of the established technologies for the better of the human
beings
Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025 the world would use 120 GW less electricity saving $100 billion a year andcutting the carbon-dioxide emissions from power plants by 350 Megatons annually
Innovations in photonics and solid state lighting will lead to trillions of dollars incost savings along with a massive reduction in the amount of energy required to lighthomes and businesses around the globe the researchers forecast In addition to theenvironmental and cost benefits of LEDs the technology is expected to enable a widerange of advances in areas as diverse as healthcare transportation systems digitaldisplays and computer networking
To bring all these things into reality there is urgent need to
a To develop mass level production to decrease cost b To adopt new technologies to reduce production costc In many energy conscious states government should enforce LED bulbs for street
lighting and other public areas to bring savings to bloated energy billsd Need more RampD efforts towards nano techlogy crystal technology used for LED
lighting
As per study or survey carried out in this report I am sure thatLED is surely a drive towards green earthhellip
So GO GREEN BY ADOPTING LEDs
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
The need of the time says that in the global world if we want to survive and moveahead in life then we have to be in the race to accept new technologies for organizationalcontrols Science has improved tremendously in every sphere of life It has eases the lifeof human and have made this world a global village where there is no boundary toachieve success
So whenever we talk of the technology to be used for the functioning of a system it doesnot indicate that it should compromise in any field Some of the major points on whichthe choice stays are
bull The technology should be efficient and updated and need automation for control
bull The life of functioning should be more for less maintenance and carefree controlsfor long time
bull The technology should be safe for every one so that everybody should be aware of the principles and equipments used
bull The updated or new technology must be capital saving that is cost effective
LED lights are the future of lighting due to many advantages Hence they are used for thecritical systems where the clear vision distant vision uniform Lux output is required andnecessary
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TRAINING REPORT ON LED LIGHTING
Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Chapter 2 NEW TECHNOLOGY
bull LED- The Future of Lighting
Light Emitting Diodes commonly called LEDs are real unsung heroes in theelectronics world They do dozens of different jobs and are found in all kinds of deviceslike digital clocks remote controls watches and indicators in home appliances Collectedtogether they can also form images on a jumbo television screen or illuminate a trafficlight
bull LED-At a Glance
Basically LEDs are just tiny light bulbs that fit easily into any electrical circuit Butunlike ordinary incandescent bulbs they dont have a filament that will burn out and theydont get especially hot They are illuminated solely by the movement of electrons in asemiconductor material and they last just as long as a standard transistor
LED is too a diode which is the simplest sort of semiconductor device Broadlyspeaking a semiconductor is a material with a varying ability to conduct electricalcurrent Most semiconductors are made of a poor conductor that has had impurities
(atoms of another material) added to it The process of adding impurities is called dopingIn the case of LEDs the conductor material is typically aluminum-gallium-arsenide(AlGaAs) In pure aluminum-gallium-arsenide all of the atoms bond perfectly to their neighbors leaving no free electrons (negatively-charged particles) to conduct electriccurrent In doped material additional atoms change the balance either adding freeelectrons or creating holes where electrons can go Either of these additions makes thematerial more conductive
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
GND POLYTECHNIC ROHINI NEW DELHI 23
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
A semiconductor with extra electrons is called N-type material since it hasextra negatively-charged particles In N-type material free electrons move from anegatively-charged area to a positively charged area
A semiconductor with extra holes is called P-type material since it effectively has extra
positively-charged particles Electrons can jump from hole to hole moving from anegatively-charged area to a positively-charged area As a result the holes themselvesappear to move from a positively-charged area to a negatively-charged area
A diode comprises a section of N-type material bonded to a section of P-typematerial with electrodes on each end This arrangement conducts electricity in only onedirection When no voltage is applied to the diode electrons from the N-type material fillholes from the P-type material along the junction between the layers forming a depletionzone In a depletion zone the semiconductor material is returned to its original insulatingstate -- all of the holes are filled so there are no free electrons or empty spaces for electrons and charge cant flow
At the junction free electrons from the N-type material fill holes from the P-type
material This creates an insulating layer in the middle of the diode called the
depletion zone
To get rid of the depletion zone we have to get electrons moving from the N-type area tothe P-type area and holes moving in the reverse direction To do this connect the N-typeside of the diode to the negative end of a circuit and the P-type side to the positive endThe free electrons in the N-type material are repelled by the negative electrode and drawnto the positive electrode The holes in the P-type material move the other way When thevoltage difference between the electrodes is high enough the electrons in the depletionzone are boosted out of their holes and begin moving freely again The depletion zonedisappears and charge moves across the diode The negative electrons in the N-type
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
material are attracted to the positive electrode The positive holes in the P-type materialare attracted to the negative electrode No current flows across the junction because theholes and the electrons are each moving in the wrong direction The depletion zoneincreases
When the positive end of the circuit is hooked up to
the N-type layer and the
negative end is hooked up
to the P-type layer free
electrons collect on one end
of the diode and holes
collect on the other The
depletion zone gets bigger
LED How It Produces Light bull
Light is a form of energy that can be released by an atom It is made up of manysmall particle-like packets that have energy and momentum but no mass These particles
called photons are the most basic units of light Photons are released as a result of moving electrons In an atom electrons move in orbitals around the nucleus Electrons indifferent orbitals have different amounts of energy Electrons with greater energy movein orbitals farther away from the nucleus
For an electron to jump from a lower orbital to a higher orbital something hasto boost its energy level Conversely an electron releases energy when it drops from ahigher orbital to a lower one This energy is released in the form of a photon A greater energy drop releases a higher-energy photon which is characterized by a higher frequency As we saw in the last section free electrons moving across a diode can fallinto empty holes from the P-type layer This involves a drop from the conduction band to
a lower orbital so the electrons release energy in the form of photons This happens inany diode but you can only see the photons when the diode is composed of certainmaterial The atoms in a standard silicon diode for example are arranged in such a waythat the electron drops a relatively short distance As a result the photons frequency is solow that it is invisible to the human eye It is in the infrared portion of the light spectrumThis isnt necessarily a bad thing of course Infrared LEDs are ideal for remote controlsamong other things Visible light-emitting diodes (VLEDs) such as the ones that light upnumbers in a digital clock are made of materials characterized by a wider gap between
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
the conduction band and the lower orbitals The size of the gap determines the frequencyof the photon and in the other words it determines the color of the light
bull Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-co
ED devices are mounted on a circuit board which can be programmed toinclude
e LEDs do not have any fusible filaments or elements They also do not containany gas
hen electricity passes through the LED the electrons passing through theDIODE
EDs are diodes which is a semiconductor device that will conduct electricity inonly on
nducting material) mounted on heat-conducting material called a heat sink andusually enclosed in a lens The resulting device typically around 7 to 9 mm on a side can be used separately or in arrays
Llighting controls such as dimming light sensing and pre-set timing The circuit
board is mounted on another heat sink to manage the heat from all the LEDs in the arrayThe system is then encased in a lighting fixture architectural structure or even a ldquolight bulbrdquo package
Thes such as Mercury or Sodium
Wunder goes an energy change and produces the light Since it is a ldquoSolid Staterdquo
light production without any gas or heating LEDs last for a very long time
Le direction The device is fabricated from layers of silicon and seeded with atoms
of phosphorus germanium arsenic or other rare-earth elements The layers of the deviceare called the die and the junction between the materials is where the light is generatedThe electricity enters from one side of the die and exits out the other As the current
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
passes through the LED device the materials that makes up the junction react and light isemitted Different materials and designs have different colored lights and intensities
bull Solid State Lighting
Lighting application that uses light-emitting diodes (LEDs) organic light-emittingdiodes (OLEDs) or light-emitting polymers are commonly referred to as solid-state
lighting
Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960rsquos The lifetime for thenew generation of LEDs is around 100000 hours of use or 30 to 40 years of normaloperation Because they are a semiconductor device they are also very rugged and arenot subject to fail when dropped or vibrated as do incandescent and fluorescent lights
The original LEDs only emitted light of one frequency or color of light Thesewere blues greens yellows oranges or reds and they were unsuited for domesticlighting Recent innovations in materials doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light
LEDs are part of a family of lighting technologies called Solid-State lightingThis family also includes OLEDs (Organic Light Emitting Diodes) OLEDs (pronouncedOH-leds) consist of sheets of carbon-based compounds that glow when a current isapplied through transparent electrodes While not yet market ready OLEDs will functionlike a thin film on a wall or ceiling that illuminates a room Like LEDs OLED
technology is advancing rapidly and can be referred as ldquoFuture of LED Lightingrdquo
bull Advantages Of Leds
While all diodes release light most dont do it very effectively In an ordinarydiode the semiconductor material itself ends up absorbing a lot of the light energy LEDsare specially constructed to release a large number of photons outward Additionally theyare housed in a plastic bulb that concentrates the light in a particular direction As youcan see in the diagram most of the light from the diode bounces off the sides of the bulbtraveling on through the rounded end
LEDs have several advantages over conventional incandescent lamps
Efficiency LEDs produce more light per watt than incandescent bulbs as inconventional incandescent bulbs the light-production process involvesgenerating a lot of heat (the filament must be warmed) This is completelywasted energy unless someone using the lamp as a heater because a huge portion of the available electricity isnt going toward producing visible light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
LEDs generate very little heat A much higher percentage of the electrical power is going directly to generating light which cuts down on the electricitydemands considerably
Color LEDs can emit light of an intended color without the use of color
filters that traditional lighting methods require This is more efficient and canlower initial costs
Size LEDs can be very small (smaller than 2 mm2) and are easily populated
onto printed circuit boards
Lower Cost in Long Run Up until recently LEDs were too expensive to usefor most lighting applications because theyre built around advancedsemiconductor material The price of semiconductor devices has plummetedover the past decade however making LEDs a more cost-effective lightingoption for a wide range of situations While they may be more expensive than
incandescent lights up front their lower cost in the long run can make them a better buy In the future they will play an even bigger role in the world of technology
OnOff time LEDs light up very quickly A typical red indicator LED willachieve full brightness in microseconds LEDs used in communicationsdevices can have even faster response times
Cycling LEDs are ideal for use in applications that are subject to frequent on-off cycling unlike fluorescent lamps that burn out more quickly when cycledfrequently or HID lamps that require a long time before restarting
Dimming LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current
Cool Light In contrast to most light sources LEDs radiate very little heat inthe form of IR that can cause damage to sensitive objects or fabrics Wastedenergy is dispersed as heat through the base of the LED
Slow Failure LEDs mostly fail by dimming over time rather than the abrupt burn-out of incandescent bulbs
Light Pattern LED lights are having a straightLinearuniform illuminatingeffect rather than distributed illuminations This property helps in longdistance vision
Lifetime LEDs can have a relatively long useful life One report estimates35000 to 50000 hours of useful life though time to complete failure may belonger They dont have a filament that will burn out so they last much longer
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Additionally their small plastic bulb makes them a lot more durable Theyalso fit more easily into modern electronic circuits
Shock Resistance LEDs being solid state components are difficult todamage with external shock unlike fluorescent and incandescent bulbs which
are fragile
Focus The solid package of the LED can be designed to focus its lightIncandescent and fluorescent sources often require an external reflector tocollect light and direct it in a usable manner
Non Toxic LEDs do not contain mercury unlike fluorescent lamps
bull Disadvantages Of Leds
High Initial Price LEDs are currently more expensive price per lumen onan initial capital cost basis than most conventional lighting technologies Theadditional expense partially stems from the relatively low lumen output andthe drive circuitry and power supplies needed However when considering thetotal cost of ownership (including energy and maintenance costs)
Temperature Dependence LED performance largely depends on theambient temperature of the operating environment Over-driving the LED inhigh ambient temperatures may result in overheating of the LED packageeventually leading to device failure Adequate heat-sinking is required to
maintain long life
Voltage Sensitivity LEDs must be supplied with the voltage above thethreshold and a current below the rating This can involve series resistors or current-regulated power supplies
Light Quality Most cool-white LEDs have spectra that differ significantlyfrom a black body radiator like the sun or an incandescent light The spike at460 nm and dip at 500 nm can cause the color of objects to be perceiveddifferently under cool-white LED illumination than sunlight or incandescentsources due to metamerism red surfaces being rendered particularly badly by
typical phosphor based cool-white LEDs However the color rendering properties of common fluorescent lamps are often inferior to what is nowavailable in state-of-art white LEDs
Area Light Source LEDs do not approximate a ldquopoint sourcerdquo of light butrather a lambertian distribution So LEDs are difficult to use in applicationsrequiring a spherical light field LEDs are not capable of providing divergence
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
below a few degrees This is contrasted with lasers which can produce beamswith divergences of 02 degrees or less
Blue Hazard There is increasing concern that blue LEDs and cool-whiteLEDs are now capable of exceeding safe limits of the so-called blue-light
hazard as defined in eye safety specifications such as ANSIIESNA RP-271-05 Recommended Practice for Photo biological Safety for Lamp and LampSystems
Blue Pollution Because cool-white LEDs (ie LEDs with high color temperature) emit much more blue light than conventional outdoor lightsources such as high-pressure sodium lamps the strong wavelengthdependence of Rayleigh scattering means that cool-white LEDs can causemore light pollution than other light sources It is therefore very important thatcool-white LEDs are fully shielded when used outdoors Compared to low- pressure sodium lamps which emit at 5893 nm the 460 nm emission spike of
cool white and blue LEDs is scattered about 27 times more by the Earthsatmosphere Cool-white LEDs should not be used for outdoor lighting near astronomical observatories
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Chapter 3 LIGHTING FACTS
bull Lux And Lumens
Lumen is the unit of light energy ndash Lux is the unit of light intensity Lumen valuesare required for engineers to decide the design of the luminnaire to ensure that therequired LUX is available for the Purpose for which the light is used For example If yourequire 100 lux for comfortable reading over 1 sq meter then you need 100 lumens If thesame 100 lux light is required over 025 sq meter area (05 x05 square) then you requireonly 25 lumens
When the light is kept at a longer distance the area covered by the light increasesin proportion to the square of the distance and lux reduces inversely with the square of the distance
Most of the lights give lights at 360 degree sphere ndash thus the light producedwithout reflectors to direct the light to a limited area gives lower lux than the same lightwith the luminnaire designed to reflect at least part of the light to where required Onehas to remember that the light reflected into the bulb such as the CFL or the tube-lightsgets absorbed into the light source itself
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
However the light given by a single diode is very small ndash say 03 to 05 of a 40W incandescent bulb In other words only if 200 - 300 LED chips (integrated or single)are used light equivalent to one normal bulb can be produced
In LED the reflectors are built in and the light output is measured after taking
into account all the losses Thus a 60 degree 1 watt LED (15 to 20 chips) can give morelight within the cone of the 60 degrees than a 40 W incandescent (360 degrees) Thus itcan be used provide where the light is required with much higher efficiency
Further LED lights can be made at very low wattages ndash 05 W or even 025W is aneconomical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL or 20 W Tube-light This enables the light to be brought near theapplication or the point of usage
Thus even a 1W LED located at 450mm (15 feet) to provide light to a work tablecan give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3
meters (distance factor of more than 18 times and angle factor of more than 15 times ndash making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered ndash due to the reflectance from the roof reflectors etc the actualfactor would be lower)
1 W of electrical energy can produce about 683 lumens at 555nm The white light being a spectrum 400 lumens per watt is considered as the maximum efficiency
The early LEDs were producing only about 2-5 lumens per watt ndash the present high bright single chip LED produce 90-110 lumens
Since energy can neither be created nor be destroyed the unconverted energy isconverted into heat The temperature of the system is dependent on the area available for radiating the heat produced Thus if the heat has to be dissipated in a small area thetemperature would be higher and vice versa The temperature also depends on theambient
Most of the LED chips are rated for maximum temperature of 80 degrees Thusin a tropical country like India with summer ambient reaching 45 degrees in the shadelarge area is required for ensuring the dissipation of heat A single chip LED dissipating005 watts requires much less area for heat dissipation compared to a 1 W LED
High bright normal LEDs are made from single chip while the power LEDs aremade from multiple diodes in a single chip The diodes are arranged in series and parallel at the time of doping The chip manufacturing of the single chip is always moreeconomical than an Integrated chip
Higher efficacies are achievable in single chip compared to multi-diode LEDThis is because of the fact that when a single LED is not performing it can be segregatedand rejected while in a multi-diode the average LED performance is taken Thus for the
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
same basic technology the multi diode LED has marginally less efficacy than the singlechip LED
In power LED higher heat dissipation takes place in a smaller area compared to the totalarea available in a single chip LED Thus power LED always requires heat sink while
single chip LEDs normally does not require heat sink
The power LEDs have diodes in series and parallel internally thus requiringhigher voltage The voltage current characteristics vary marginally between the diodesHence the single voltage control does not guarantee proper current control for each parallel string In single diode strings each string can be grouped for current limitingeliminating the need for expensive driver circuits a simple reliable AC current limitingcircuit using just passive component is sufficient for normal LEDs thus providing veryhigh reliability with low cost circuitry
bull Color temperature and color Rendering index
Many optical energy applications require high intensity spatially uniform whitelight that does not significantly heat the surrounding environment in the near field andor far field More specifically many applications require correlated color temperatures(ldquoCCTrdquo) between 4100-4900K (ie white light) with a color rendering index (ldquoCRIrdquo) between 90 amp 100
Correlated color temperature (ldquoCCTrdquo) is a numerical assignment of the apparentcolor of a light source (ie as viewed by the human visual system) and is measured indegrees Kelvin Color rendering is how well a light source renders color (ie in thecourse of interacting with an object) as compared to how well daylight renders color (ie
in the course of interacting with the same object)
Traditional light sources however suffer from for example but not limited tocombinations of a poor CRI poor CCT poor intensity short usage life large power electrical consumption large package size thermal energy andor are electrically and or optically inefficient
Tungsten filament lamps for example while providing high intensity opticalenergy with high CRI values emit optical energy that has a poor CCT (ie about 3000Kwhich correlates to the color yellow) for white light applications In addition tungstenfilament lamps have a low electrical to optical efficiency and thus require large amounts
of electrical power to generate high intensity optical energy which results in largequantities of thermal energy Furthermore high power tungsten lamps have a low lamplifetime usually operating for about 500 hours
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
LAMP TYPE LUMENW CRI CCT
(K)
LIFE EFFICIENCY
Standard Incandescent 5-20 100 3000 750-1000 3-10
Tungsten Halogen 15-25 100 4000 2000-4000
7-12
Compact Fluorescent 2055 80 10000 10-27Mercury Vapour 25-50 15-30 24000 20-40
Metal Halide 45-100 60-90 5000 20000 36-80
High Pressure Sodium 45-110 9-70 24000 36-88
LED Based 90-110 90-100
4100-4900
gt50000 25-60
bull Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the
basis of luminous efficacy To compare LED sources to CFLs for example the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt Data sheets for white LEDs from the leading manufacturers will generally provide ldquotypicalrdquo luminous flux in lumens test current (mA) forward voltage (V) and junction temperature (Tj) usually 25 degrees Celsius To calculate lmW divide lumens by current times voltage As an example assume a device with typical flux of 45 lumensoperated at 350 mA and voltage of 342 V The luminous efficacy of the LED sourcewould be 45 lumens (35 amps times 342 volts) = 38 lmW To include typical driver losses multiply this figure by 85 resulting in 32 lmW Because LED light output issensitive to temperature some manufacturers recommend de-rating luminous flux by10 to account for thermal effects In this example accounting for this thermal factor
would result in a system efficacy of approximately 29 lmW However actual thermal performance depends on heat sink and fixture design so this is only a very roughapproximation Accurate measurement can only be accomplished at the luminnaire level
bull Application Efficiency
While there is no standard definition of application efficiency manufacturers usethe term here to denote an important design consideration that the desired illuminancelevel and lighting quality for a given application should be achieved with the lowest practicable energy input Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other lightsources
Due to the directional nature of their light emission LEDs potentially have higher application efficiency than other light sources in certain lighting applications Fluorescentand standard ldquobulbrdquo shaped incandescent lamps emit light in all directions Much of thelight produced by the lamp is lost within the fixture reabsorbed by the lamp or escapes
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
from the fixture in a direction that is not useful for the intended application For manyfixture types it is not uncommon for 40-50 of the total light output of the lamp(s) to belost before it exits the fixture
LEDs emit light in a specific direction reducing the need for reflectors and
diffusers that can trap light so well-designed fixtures like the under cabinet light shown below can deliver light more efficiently to the intended location
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Chapter 4 HOW TO PRODUCE LEDs
bull Raw Materials
Diodes in general are made of very thin layers of semiconductor material onelayer will have an excess of electrons while the next will have a deficit of electrons Thisdifference causes electrons to move from one layer to another thereby generating lightManufacturers can now make these layers as thin as 5 micron or less (1 micron = 1 ten-thousandth of an inch)Impurities within the semiconductor are used to create therequired electron density
To complete the device it is necessary to bring electricity to it and from it Thuswires must be attached onto the substrate These wires must stick well to thesemiconductor and be strong enough to withstand subsequent processing such assoldering and heating Gold and silver compounds are most commonly used for this
purpose because they form a chemical bond with the gallium at the surface of the wafer
LEDs are encased in transparent plastic the plastic can be any of a number of varieties and its exact optical properties will determine what the output of the LED lookslike
bull Making Semiconductor Wafers
First a semiconductor wafer is made The particular material composition isdetermined by the color of LED being fabricated Single semiconductor wafer isformed with the help of encapsulation method thing like baking of a cake
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them fromescaping into the pressurized gas in the chamber they are often covered with a
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
GND POLYTECHNIC ROHINI NEW DELHI 19
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
layer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly The solution cools and crystallizes on the end of the rod as it is lifted outof the chamber forming a long cylindrical crystal ingot The ingot is then slicedinto wafers- liquid encapsulation method
The bowl is then sliced into very thin wafers of semiconductor approximately 10mils thick or about as thick as a garbage bag The wafers are polished until thesurfaces are very smooth so that they will readily accept more layers of semiconductor on their surface The principle is similar to sanding a table before painting it
Next the wafers are cleaned through a rigorous chemical and ultrasonic processusing various solvents This process removes dirt dust or organic matter that mayhave settled on the polished wafer surface The cleaner the processing the better the resulting LED will be
bull Adding Epitaxial Layers
Additional layers of semiconductor crystal are grown on the surface of the waferlike adding more layers to the cake This is one way to add impurities or dopantsto the crystal The crystal layers are grown this time by a process called LiquidPhase Epitaxy (LPE) The deposited layers will become a continuation of thewafers crystal structure
To make the semiconductor wafers gallium arsenic andor phosphor are firstmixed together in a chamber and forced into a solution To keep them from
escaping into the pressurized gas in the chamber they are often covered with alayer of liquid boron oxide Next a rod is dipped into the solution and pulled outslowly
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
GND POLYTECHNIC ROHINI NEW DELHI 19
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
The solution cools and crystallizes on the end of the rod as it is lifted out of thechamber forming a long cylindrical crystal ingot The ingot is then sliced intowafers
LPE creates an exceptionally uniform layer of material which makes it a preferred growth and doping technique The layers formed are several micronsthick
After depositing epitaxial layers it may be necessary to add additional dopants toalter the characteristics of the diode for color or efficiency
bull Adding Metal Contacts
Metal contacts are then defined on the wafer The contact pattern is determined inthe design stage and depends on whether the diodes are to be used singly or incombination
Wafer bonding Technology the metal and the semiconductor bond together chemically so the contacts dont flake off
bull Mounting amp Packaging
Individual dies are mounted on the appropriate package A tiny gold wire issoldered to the other lead and wire-bonded to the patterned contacts on the surfaceof the die In wire bonding the end of the wire is pressed down on the contactmetal with a very fine needle The gold is soft enough to deform and stick to a likemetal surface
The entire assembly is sealed in plastic The wires and die are suspended inside amold that is shaped accordingly The epoxy is cured and the package is complete
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Chapter 5 MARKET POTENTIAL
bull Lighting Industry Review
Total Electricity Consumption for India ndash 1 20 000 MWTotal Consumption from Lighting Sector ndash 30 000 MW (19)Total Electrified households at present ndash 112 millions (5 growth rate)Total non Electrified households at present ndash 78 millions
LED lighting products market is still at a nascent stage in India As per theindustry estimates Indian lighting industry LED lighting products market is still at anascent stage in India Its share is mere 200 Crores in the Rs 6500 crore Indian lightingindustries
bull Market Potential In India
SEGMENT AND TOTAL VALUE In Crores
STREET LIGHTING 1376
FACTORY LIGHTING 522
DOMESTIC amp COMM LIGHTING 143
HOARDING 5
SIGNAGE 86
INDOOR LIGHT 4158
5000
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TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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httpslidepdfcomreaderfullcomplete-report-jatin 2649
TRAINING REPORT ON LED LIGHTING
bull Market Survey In India
VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category 2005 2006 2007 2008 2009 2010 2011 2012
GLS Lamps 600 690 725 762 800 841
FTL 1100 1210 1270 1333 1399 1468
CFL 700 830 1162 1627 2278 3189
Special Lamps 400 440 560 713 907 1155
Total 3700 4170 4837 5689 6789 8226 (CRORES)
Luminaires 900 1000 1120 1254 1405 1574
Control Gears and High Masts 200 210 248 293 346 408
Accessories 200 205 236 272 313 360
Components 200 220 260 307 363 429
Total 4300 4805 5581 6561 7811 9424 (CRORES)
LED LIGHTING 197 213 231 250 271 (CRORES)
CAGR 803
CRORE
CRORE
GND POLYTECHNIC ROHINI NEW DELHI 20
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TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
GND POLYTECHNIC ROHINI NEW DELHI 21
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
GND POLYTECHNIC ROHINI NEW DELHI 22
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
GND POLYTECHNIC ROHINI NEW DELHI 23
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 2749
TRAINING REPORT ON LED LIGHTING
bull PRODUCTION TRENDS IN INDIA
Category 2005 2006 2007 2008 2009 2010 2011 2012
A Incandescent Lamps 711 757 779 734 551 275 0 0
B Fluorescent Lamps 180 186 190 186 156 109 77 0
C Compact Fluorescent Lamps 67 100 140 199 299 448 672 1007
D Special Lamps 10 14 17 21 27 35 46 60
TOTAL Total 968 1057 1126 1140 1033 868 794 1067
E LED LAMPS 0 0 0 0 313 719 1079 1143
Total 968 1057 1126 1140 1345 1587 1873 2210
E 0 0 0 0 23 45 58 52
PRODUCTION TRENDS IN INDIA (MILLION PIECES)
TOTAL SHARE OF LED MARKET
2005 ndash 2008 TRENDS
2009 ndash 2012 TRENDS
GND POLYTECHNIC ROHINI NEW DELHI 21
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
GND POLYTECHNIC ROHINI NEW DELHI 22
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
GND POLYTECHNIC ROHINI NEW DELHI 23
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Chapter 6 CASE STUDIES
bull Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering While this may not be very important for outdoor lighting of thestreets (street lights) the LED lamps may offer a wider range of spectral content makingit a preferred lamp due to superior color rendering So even if it turns out that it takesnearly the same amount of power to operate a LED cluster for 14000 lumens as it doesfor one 150 Watt HPSV lamp the real question is which lamp is going to give the best performance over time
The light output used for various street light sources are compared below
Typical Lamp Lumen output in lumenswatt is as follows
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I amp II) -1970are as follows
HPSVL 80-90
Halogen lamp 15-20
Fluorescent Tubular Lamps T12 50-60
Fluorescent Tubular Lamps T 8 55-60
Fluorescent Tubular Lamps T 5 80-90
LED Lamp 90-114
Classification
of Lighting
Installation
Type of Road Average Level
of
Illumination
on Road
Surface
Ratio
Minimum
Average
Illumination
Group A1 Important traffic routes carrying fasttraffic
30 Lux 04
Group A2 Other main roads carrying mixedtraffic like main city streets arterialroads throughways etc
15 Lux 04
Group B1 Secondary roads with considerabletraffic like principal local trafficroutes shopping streets etc
8 Lux 03
Group B2 Secondary roads with light traffic 4 Lux 03
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
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TRAINING REPORT ON LED LIGHTING
Recent advances in LED technology have made LED streetlamps more viablethan ever When typical LED output was 40 to 50 lumens per watt at 350 mA a fixturewould require so many LEDs around 150 to meet the roadway lighting illuminationstandards it would be oversized (and therefore potentially unstable and unsafe) not tomention cost-prohibitive But now that LEDs provide outputs of 80 to 100 lumens at 350
mA the same streetlamp fixture would only require about 75 LEDs to satisfy theroadway pattern specifications resulting in a more compact stable fixture design that isalso much more cost efficient than traditional lighting technologies
The power supply to the light is 220V AC 50 Hz Inside the fixture there areseveral SMPS that provide an output of 24 V DC and 350 mA Each SMPS drives a chipconsisting of 7 one watt high powered LEDs So approximate LEDs required will bearound 65 it can vary as per the capacity of street light and lmw of LED The life of theLEDs is 100000 hours
The equivalent LED Luminaries to the conventional luminaries are as follows
Type Wattage To be replaced byhellip
HPSV 150W 24 LED with consumption of 40 W
HPSV 250W 36 LED with consumption of 55 W
HPSV 70 W 12 LED with consumption of 20 W
Halogen Lamp 50 W 50 W 5 LED with consumption of 8 W
Halogen Lamp 150 W 150 W 24 LED with consumption of 40 W
Now we will consider only first two cases
Comparison of 150 W sodium Vapour Lamp with 24 LED systems
Sodium
Vapour
Lamp
150w + 25w(ballast)
175 wLux Level20 ndash 25
175 WattLoad175x12x365x61000=Rs4599fixture
Electric Billfor 100 poles for 1year Rs459900-
LED Based
Lamp
Pole Ht 6 m
40w 40 wLux Level10 ndash 12
40x12x365x6 1000=Rs1051 fixture
Electric Billfor 100 poles for 1year
Rs105100-
Saving=3548- per fixture
GND POLYTECHNIC ROHINI NEW DELHI 23
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TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
GND POLYTECHNIC ROHINI NEW DELHI 26
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
GND POLYTECHNIC ROHINI NEW DELHI 28
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
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TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
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TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
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TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
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TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
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TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
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TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
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TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
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TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3049
TRAINING REPORT ON LED LIGHTING
Comparison of 250 W sodium vapour lamp with 36 LED systems
Sodium
Vapour
Lamp
250w + 35w(ballast)
285 wLux Level25 ndash 30
285 WattLoad285x12x365
x6 1000=Rs7490fixture
Electric Billfor 100 poles for 1
year Rs749000-
LED Based
Lamp
Pole Ht 8 m
55w 55 wLux Level15 ndash 18
55x12x365x61000=Rs1445fixture
Electric Billfor 100 poles for 1year Rs144500-
Saving=6045- per
fixture
Note Rs 6- is considered as Energy rate per unit
SAVING CALCULATION FOR DELHI STREET LIGHTS
SODIUM VAPOUR
LIGHT TO BE
REPLACED
LED LIGHT
No of Lamps 400000 400000
Wattage of Lamps 250 40
Power Consumption in Watts 250 40
No of hours of Operation per day
8 8
PRICE COMPARISONCost of Fixture 1000 2000
Cost of LED Light 7000 13000
Power consumedDay6 096
Power consumedYear 2190 3504
Power costAnnum 13140 21024
Savings with LED Lamps per Year
110376
Cost of Maintenance 0
Total savingsYear 141912
ROI for new Installation 094608
EMISSIONS
CO2 (085unit) 29784
S02 (000795unit) 279
No2 (000356unit) 125
Total GHG Emissions 30187
GND POLYTECHNIC ROHINI NEW DELHI 24
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3149
TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
GND POLYTECHNIC ROHINI NEW DELHI 25
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TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
GND POLYTECHNIC ROHINI NEW DELHI 26
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
GND POLYTECHNIC ROHINI NEW DELHI 27
842019 Complete Report Jatin
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
GND POLYTECHNIC ROHINI NEW DELHI 28
842019 Complete Report Jatin
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
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TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
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httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
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TRAINING REPORT ON LED LIGHTING
Chapter7ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM
To do comparison between three different types LEDs
bull EDISON 1 W Part noEDEW-ILA5
bull SEOUL 1 W Part no 42180U2 ( LOT 1)
bull SEOUL 1 W part no42180U2 (LOT 2)
APPARATUS
3 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter power supply
PROCEDURE
bull First all 3 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe different different readings at differentdifferent positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
GND POLYTECHNIC ROHINI NEW DELHI 25
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3249
TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
GND POLYTECHNIC ROHINI NEW DELHI 26
842019 Complete Report Jatin
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TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
GND POLYTECHNIC ROHINI NEW DELHI 27
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3449
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
GND POLYTECHNIC ROHINI NEW DELHI 28
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3549
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3649
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
GND POLYTECHNIC ROHINI NEW DELHI 30
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3749
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
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httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
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TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
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TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3249
TRAINING REPORT ON LED LIGHTING
B
SOURCE
Ө2
C
A Ө2
D
OBSERVATIONS
LED
PARAMETER
EDISON
EDEW-ILA5 SEOUL
42180U2 (LOT
1)
SEOUL
42180U2 (LOT
2)
FORWARD VOLTAGE (V) 31 33 31
CURRENT TAKEN (mA) 360 360 360
SPREAD ANGLE (deg) 135 127 127
LUX (lx) 1 M 219 271 252
SCREEN
GND POLYTECHNIC ROHINI NEW DELHI 26
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3349
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
GND POLYTECHNIC ROHINI NEW DELHI 27
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3449
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
GND POLYTECHNIC ROHINI NEW DELHI 28
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3549
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3649
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
GND POLYTECHNIC ROHINI NEW DELHI 30
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3749
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3349
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 2
AIM
To do comparison between four different types LEDs
bull OSRAM 1 W Part no LUWWSAM-LxLybull AVAGO 1 W Part noASTM-MW009-NMM00
bull CREE 1 W Part NoXREWHT-L1-0000-A01
bull PHILIPS REBEL LUXEON 1 W Part no LXML-PWC1-0090
APPARATUS
4 different LEDs metal PCB solder soldering iron heat sink multimeterLux meter and power supply
PROCEDURE
bull First all 4 LEDs are mounted on the metal PCB with the help of solder ampsoldering iron amp paste them on heat sink
bull Supply is given through an AC to DC converter
bull Measure Voltage amp current using multimeter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source ( LED )
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
GND POLYTECHNIC ROHINI NEW DELHI 27
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3449
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
GND POLYTECHNIC ROHINI NEW DELHI 28
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3549
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3649
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
GND POLYTECHNIC ROHINI NEW DELHI 30
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3749
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3449
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
LED
PARAMETER
OSRAM
LUWWSAM-LxLy
AVAGO
ASTM-MW009-
NMM00
CREE
XREWHT-L1-0000-
A01
PHILIPS
REBEL
LUXEONLXML-
PWC1-0090
FORWARD VOLTAGE
(V)
326 316 326 329
CURRENT TAKEN
(mA)
350 350 350 350
SPREAD ANGLE (deg) 74 70 62 57
LUX (lx) 1 M 219 278 40 362
GND POLYTECHNIC ROHINI NEW DELHI 28
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3549
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3649
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
GND POLYTECHNIC ROHINI NEW DELHI 30
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3749
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3549
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 3
AIM
To compare two bunches of Nine LEDs on the basis of three parameters-Lux Spread amp Spread Angle First of EDISON make EDEW-ILA5 ampsecond of SEOUL make 42180U2
To calculate Lux Spread amp Spread angle of a Focus Light using LUXMeter
APPARATUS
Nine EDISON EDEW-ILA5 LEDs Nine SEOUL 42180U2 LEDs2 nine LEDsMetal PCBs solder soldering iron multimeter Lux meter and power supply
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now we have two different groups of LEDs-one is of EDISON make LEDsamp second is of SEOUL make LEDs
bull Now give them power supply through an AC to DC converter
bull Now go in Dark Room for measuring Lux amp Spread Angle
bull Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs)
bull Now with the help of Lux Meter observe the different different readings atdifferent different positions
bull Where you get a maximum value mark it as C
bull Now calculate the half of the measured value and observe that half value at bothupward amp downward directions from A using Lux Meter Also mark those pointsas B amp D
bull Calculate the distance between B amp D in cm using Measuring-Tape
bull We know that BC=CD=BD2Using formula tan(Ө2)=BCAC where AC=1meter amp BC=BD2
bull Total spread angle=Ө2+Ө2=Ө
bull Similarly follow the same procedure for calculating all three parameters of theFocus Light amp note down in observation table
GND POLYTECHNIC ROHINI NEW DELHI 29
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3649
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
GND POLYTECHNIC ROHINI NEW DELHI 30
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3749
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3649
TRAINING REPORT ON LED LIGHTING
OBSERVATIONS
BUNCH OF
PARAMETER
EDISONEDEW-
ILA5
(Without
Lens)
EDISONEDEW-
ILA5
(With Lens)
SEOUL42180U2
(Without
Lens)
SEOUL42180U2
(With Lens)
LUX ( lx ) 1 M 190 3316 198 2734
SPREAD ( Cm ) 149 35 153 40
SPREAD ANGLE(deg) 73 19 74 22
Complete track light readings with the lot one Seoul W42180 U2
LUX ( lx ) 1 M 2916 SPREAD ( Cm ) 20
SPREAD ANGLE (deg) 11
GND POLYTECHNIC ROHINI NEW DELHI 30
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3749
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3749
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 4
AIM
To connect 10 LEDs in series amp to mount them on a heat sink To test 4 channel output NEC LED driver 40 W DC-DC boost driver
APPARATUS
10 LEDs metal PCBs solder soldering iron multimeter NEC LED driverDC power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective metal PCBs using solder amp solderingiron Now paste all metal PCBs on a heat sink amp join them all in series with oneanother using connecting wires
bull Now connect a DC supply to NEC LED driver amp connect its output as input power supply to bunch of 10 LEDs
bull Using Multimeter measure input voltage amp input current of DC power supply
bull Now measure voltage amp current at the four different channels of the NEC LEDdriver amp record in observation table
OBSERVATIONS
BATTERY INPUT VOLTAGE - 1346 VBATTERY INPUT CURRENT - 153 A
CHANNEL No VOLTAGE ( V ) CURRENT ( mA )
1 315 530
2 317 530
3 318 530
4 318 540
GND POLYTECHNIC ROHINI NEW DELHI 31
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3849
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 5
AIM
To compare two High Bay lights models on the basis of their Lux outputHighbay models Super flux LEDs model ndashTriton
Power LEDs model- Nebula
APPARATUS
2 High bay light (One is made up of 60 Power LEDs amp second one is made up of 792 Super Flux LEDs) Lux meter measuring tape amp power supply
PROCEDURE
bull This experiment should be done only after sunset First mount the light at a heightof 9m from the ground
bull Make it glow by connecting it to the normal 230 V AC supply
bull Mark the centre as C on the ground amp mark the positions exactly above amp belowthe Centre measuring a distance of 1m using measuring tape Name these pointsas A amp B
bull Now from A amp B mark exactly 5 points at a distance of 1m from each other amp on both the sides (Left amp Right)
bull Now with the help of Lux Meter take readings at all these points
GND POLYTECHNIC ROHINI NEW DELHI 32
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 3949
TRAINING REPORT ON LED LIGHTING
LUX LEVEL ANALYSIS
37 lux c
35 lux
31 lux
25 lux
19 lux
14 lux
LUX READINGS OF HIGH BAY SFL- TRITON
100 lux
Mounting height 9 M
86 lux
50 lux
29 lux
17 lux
10 lux
LUX READINGS OF HIGH BAY PL-NEBULA
Mounting height 9 M
GND POLYTECHNIC ROHINI NEW DELHI 33
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4049
TRAINING REPORT ON LED LIGHTING
ASSIGNMENT 6
AIM
To make a LED Street Light using 12 AVAGO 1 W part noASTM-MW009-NMM00 LEDs amp observe its Lux amp Spread using Lux Meter
APPARATUS
Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs Star MetalPCBs solder soldering iron multimeter power supply amp connecting wires
PROCEDURE
bull First we mount all LEDs on their respective Star Metal PCBs using solder amp
soldering iron Connect them in series with one anotherbull Place the light at a distance of 9 Feet 12 Feet amp 15 Feet one by one from the
screen (wall) amp connect an AC supply to it
bull Using Lux Meter measure its Lux amp Spread Angle Note in observation table
OBSERVATIONS
DISTANCE(ft) LUX(lx) SPREAD(cm) SPREAD ANGLE()
9 50 450 796
12 35 480 673
15 21 502 583
GND POLYTECHNIC ROHINI NEW DELHI 34
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4149
TRAINING REPORT ON LED LIGHTING
APPENDIX PHOTO GALLERY
Photo 1 Types of Watt LEDs with Star MC PCB
Photo 2 Thermal bonding compound from Electro lube
GND POLYTECHNIC ROHINI NEW DELHI 35
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4249
TRAINING REPORT ON LED LIGHTING
Photo 3 LEDs Testing Arrangement ( Heat sink)
Photo 4 Complete LEDs Testing Arrangement
GND POLYTECHNIC ROHINI NEW DELHI 36
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4349
TRAINING REPORT ON LED LIGHTING
Photo 5 Temperature Controlled Soldering Station for soldering the LEDs without
damaging
Photo 6 Chromo Meter cum Lux meter for measurement of Lux
GND POLYTECHNIC ROHINI NEW DELHI 37
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4449
TRAINING REPORT ON LED LIGHTING
Photo 7 Complex LUX Meter shows reading with coordinates
Photo 8 Simplest LUX Meter
GND POLYTECHNIC ROHINI NEW DELHI 38
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4549
TRAINING REPORT ON LED LIGHTING
Photo 9 Dark Room for Lux readings and testing
Photo 10 Testing in Dark Room ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 39
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4649
TRAINING REPORT ON LED LIGHTING
Photo 11 LEDs Testing Arrangement
Photo 12 12 W LED based Street Light
GND POLYTECHNIC ROHINI NEW DELHI 40
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4749
TRAINING REPORT ON LED LIGHTING
Photo 13 Focus Lightrsquos LEDs with Lens amp Diffuser ( Assignment no 3)
Photo 14 Testing of Lens amp Diffuserrsquos Effect on Light ( Assignment no 3)
GND POLYTECHNIC ROHINI NEW DELHI 41
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4849
TRAINING REPORT ON LED LIGHTING
Photo 15 Track Light Prototype (view 1)
Photo 16 Track Light Prototype (view 2)
GND POLYTECHNIC ROHINI NEW DELHI 42
842019 Complete Report Jatin
httpslidepdfcomreaderfullcomplete-report-jatin 4949
TRAINING REPORT ON LED LIGHTING
Photo 17 Track light Prototype (view 3)
Photo 18 Sealed IP65 constant current SMPS Driver Used in Track Light