Looking to save on energy costs and improve the performance of your facility’s lighting system? High-bay fluorescents have long been a staple in industrial and commercial spaces, but as technology advances, their limitations become increasingly clear. Frequent maintenance, high energy consumption, and outdated performance are challenges that facility managers and electricians know all too well.
The solution? Retrofitting high-bay fluorescent fixtures to LEDs. It’s a growing trend, and for good reason. LED lighting offers huge benefits for stakeholders and facility staff. This post will walk you through the different ways you can retrofit high-bay fluorescents to LED. We’ll cover the benefits of making the switch, the steps required for retrofitting, and tips for getting the best ROI.
Why Retrofit Fluorescent High-Bay Lights to LED?
Cost Savings
Switching to LED lighting delivers substantial financial benefits for industrial and commercial facilities. LEDs use far less electricity than fluorescent lights, which immediately cuts down your monthly energy bills.
Additionally, LED lights are designed to last much longer. In fact, they boast up to 50,000 hours of performance compared to the typical 15,000 hours of fluorescent tubes. A longer lifespan requires fewer replacements, which will save you money on maintenance costs.
For example, if you operate a warehouse with 50 high-bay fluorescent fixtures that run 10 hours a day, replacing those lights with LEDs could reduce your annual energy costs by hundreds or even thousands of dollars.
Energy Efficiency
LEDs are built for efficiency. They convert a higher percentage of energy into light, meaning less waste in the form of heat. On average, LEDs consume less than half the energy used by their fluorescent counterparts. That makes a huge difference when lighting a large industrial facility or warehouse. Beyond cost savings, improved energy efficiency also reduces your facility’s environmental impact, shrinking your carbon footprint and supporting green initiatives.
Enhanced Performance
Beyond cost and energy savings, the light quality of LEDs outperforms fluorescent tubes in every category. High-bay LEDs provide brighter, more consistent lighting, making them ideal for illuminating large spaces with high ceilings. They also offer superior color rendering, meaning your space will look clearer and more natural, enhancing safety and productivity in work environments.
Further, LEDs perform better than fluorescents in cold temperatures, making them suitable for cold storage warehouses and refrigerated storage areas.
Preparing for Your Retrofit Project
Assess Your Current Setup
Before you retrofit, take stock of your existing fluorescent fixtures. Assess their condition, wattage, and layout. Are the fixtures in good shape, or are they showing signs of wear? What wattage do your fluorescents currently use, and how much light do your workspaces require? Knowing these details helps you determine whether to retrofit with LED tubes or replace the entire fixture.
Select the Right LED Tubes
Compatibility matters when choosing LED tubes. Look for LED T8 or T5 tubes that meet your lumens and color temperature preferences. For instance, a 5000K color temperature is ideal for bright, daylight-like lighting in large spaces.
Don’t forget to check product warranties. A good warranty reflects a manufacturer’s confidence in the quality and durability of their LEDs.
Option #1: Retrofitting With Ballast-Compatible (Plug-and-Play) LED Tubes
Ballast-compatible LEDs, also known as plug-and-play LEDs, allow you to retrofit your high-bay fluorescents without the need to rewire the fixture. The ballast is a component within fluorescent tubes that regulates the electrical current to the bulb to provide consistent light. Ballast-compatible LED tubes look like fluorescent tubes and are designed to work directly with existing fluorescent fixtures and ballasts. This trait makes installation quick and straightforward.
How To Install Plug-and-Play LEDs:
- Turn off the power supply at the breaker panel.
- Remove the fluorescent tubes from the fixture.
- Insert the ballast-compatible LED tubes into the existing fixture.
- Turn the power back on and test the lights.
Pros and Cons
This option is easy to implement and minimizes downtime since you don’t need to rewire the fixture. However, the long-term drawback is that the fluorescent ballast remains in use, meaning you may need to replace or maintain it down the line. Compatibility can also be an issue, so ensure the LED tube is rated for your ballast type.
Option #2: Retrofitting With Direct-Wire (Bypass Ballast) LED Tubes
Direct-wire LED tubes bypass the ballast completely, directly connecting to the power supply. This option requires an electrician to rewire the power to the fixture. Bypass ballast LED tubes can provide improved efficiency while preventing the need for future ballast maintenance or replacement.
How To Install Direct-Wire LEDs:
- Turn off the power supply at the breaker panel.
- Remove the fluorescent tubes and disconnect the ballast from the fixture.
- Rewire the fixture according to the LED manufacturer’s instructions. This step completes the circuit to make up for the removal of the ballast.
- Insert the direct-wire LED tubes into the fixture.
- Turn the power back on and test the new lights.
Pros and Cons
This method provides better energy efficiency since there’s no ballast to consume extra power. It also eliminates future compatibility worries and reduces long-term maintenance. However, the rewiring process is complex, and we highly recommend consulting a licensed electrician if you’re unfamiliar with electrical work.
Option #3: Replacement of the Fluorescent High-Bay Fixture
If your current fixtures are outdated or damaged, replacing them with modern LED high-bay fixtures may be the most effective option. While this isn’t technically retrofitting, it does allow you to switch from fluorescents to LEDs.
How To Install a New High-Bay Fixture:
- Turn off the power supply at the breaker panel.
- Disconnect and remove the old fluorescent fixture.
- Install the new LED high-bay fixture according to the manufacturer’s instructions.
- Restore power and test the new lighting setup.
This option requires a higher upfront investment but offers the latest in LED technology, including features like motion sensors and advanced dimming capabilities.
Common Mistakes To Avoid During Retrofit Projects
- Skipping the initial assessment: Failing to evaluate your existing fixtures can result in purchasing incompatible LED tubes or overlooking necessary repairs.
- Choosing the wrong LED tubes: The LED tubes must meet your fixture’s specifications and your workspace’s lighting requirements.
- Neglecting safety precautions: Always turn off power at the breaker before installation. Also, follow manufacturer instructions closely. For rewiring projects, consult a licensed electrician.
Your Next Step Toward Efficient Lighting
Retrofitting high-bay fluorescents to LEDs is one of the best decisions you can make for your facility. The two primary methods, ballast-compatible and direct-wire retrofits, offer clear benefits, from lower energy use to reduced maintenance demands.
By making the switch to LED, you’ll improve your facility’s efficiency, lower operating costs, and enhance lighting performance for years to come. Looking for expert guidance or high-quality retrofitting products? Contact our team today to discover the best ways you can retrofit your lights.
