P08428 LED Lighting Technologies for a Sustainable Entrepreneurial Venture Team Members Shawn Russell Project Manager David Eells Mechanical Engineer Taylor Shivell Arthur Deane Electrical Engineer Phil Pietrantoni Christine Lagree Industrial Engineer Sponsor: RIT Facilities Management Services

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

Project Description Create a new walkway lighting system with the use of LEDs Primary market is RIT Facilities Management Services Current annual cost to maintain and power 125 residential lights: $10,020 Customer Needs Engineering Specifications Long lifetime Design for 30 years Color temperature comparable to metal halide Color temperature between 3500K-5400K Provide as much light as current system ½ -2 ft-cd on walkway (spread of 80’x12’)

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

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

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

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

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

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

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

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

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

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

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

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

Sustainability (Metric # 4, 5, & 19) Fuel Sources: Hess Biomass <1% Coal 31% Gas 23% Hydro 11% Nuclear Oil 12% Solar 0% Solid Waste Wind CO2 Emissions   LED MH kWh/year/fixture 262.80 722.70 kWh for 125 fixtures 32,850.00 90,337.50 Annual lbs/kWh/fixture 311.89 857.70 Annual lbs/kWh/125 fixtures 38,986.38 107,212.55 lbs/kWh for NY 0.86 lbs/kWh for Hess/RIT 1.1868 http://www.eia.doe.gov/oiaf/1605/ee-factors.html

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

Questions