Making the Move From HID to LED Painless, Easy and Cost Effective. Appleton Mercmaster LED Low Profile Luminaires Technology and Application Guide.
Maximize Operating Expense Budgets and Reduce Maintenance Costs with this Easy-to-Install Retrofit Solution. Designed for low mounting height applications in harsh industrial and hazardous environments, the Appleton Mercmaster LED Low Profile by Emerson features interchangeable, field replaceable globes, a lightweight, compact profile, versatile mounting hoods, retrofit adapters, and variety of color temperature options. Providing a true one-to-one retrofit solution, this luminaire can handle mounting height and application challenges with just one fixture. Rugged and corrosion-resistant, this luminaire is certified for Class I, Division 2, Class II, and Class III hazardous locations, rated for use in marine and wet locations, and is globally certified for ATEX/ IECEx Zone 2, 21 and 22. A superior thermal design paired with an IP66/67 LED driver translates to maintenance-free operation for years to come. 1 Transitioning from a High Intensity Discharge (HID)/legacy light source to an LED luminaire has never been easier with the Mercmaster LED Low Profile. This product allows you to utilize existing mounting hoods and conduit/wiring systems, keeping your retrofit installation labor costs down. Additionally, optional adapters allow fixtures to mate with a wider range of mounting hoods (Emerson and other manufacturers), letting facilities like yours consolidate with a single luminaire.
A Single Fixture Solution for All of Your Low Mounting Height Applications in Hazardous and Industrial Locations The Mercmaster LED Low Profile is an easy-to-install solution that is well suited for low mounting height applications. The retrofit mounting adapters can be used with Emerson s Appleton brand and other manufacturers legacy HID mounting hoods to achieve a true one-to-one retrofit solution. The prismatic glass refractor, shown below on the left, provides an optimal light distribution with minimal glare. It is an ideal lighting solution for mounting heights under 6.1 m (20 ft). Superior thermal heat sink design provides cool operation from 40 C to +65 C ( 40 F to +149 F) wide enough for any environment. Mounting Adapters for Legacy HID fixture retrofits. IP66/IP67, NEMA 4X Compact size and low weight for single person installation. Available in three color temperatures: 5000K, 4000K and 3000K. 6KV standard surge protection protects your investment and keeps your facility up and running. Replaceable globes and LED drivers extend luminaire life even beyond 100,000 hours. IMLLED2/MLLED2 - IMLLED4/MLLED4 3,300 to 5,500 Lumens (70 to 175 W HID) 6 to 20 ft (1.5 to 6.1 m) Mounting Heights NEC/CEC certified only. Ease of Installation Allowing facilities to utilize existing mounting hoods and conduit/wiring systems, the Mercmaster LED Low Profile helps lower labor costs during replacements and retrofits. Additionally the retrofit adapters enable fixtures to mate with a wider range of mounting hoods, letting you consolidate your facility with a single luminaire. Global Certifications With certifications for ATEX/IECEx Zone 2, 21 and 22, and NEC/CEC Class I, Division 2, Class II, Division 1 and 2, Class 3, and Zones 2 and 21, the Mercmaster LED Low Profile s unique thermal design ensures cool operation for a long, virtually maintenance-free life, and safe use in any harsh industrial and hazardous global environment. Versatile Mercmaster LED Low Profile s field replaceable globes allow for the retrofitting of a space at a variety of mounting heights, using just one fixture. The four globe assemblies can be quickly removed and changed depending on the application. Engineered to Be Lightweight, Rugged, and Compact This low profile luminaire weighs only 4.6 kg (10.1 lbs) and has an installed profile of just 170.2 mm (6.7 in), making it ideal for low mounting heights and tight spaces. The electrostatically applied powder coat finish provides exceptional corrosion resistance in the toughest environments. Our unique latch assembly and hinge construction design assures 360 compression at all points on the driver housing gasket for positive sealing. 2
Life of a Luminaire - HID vs. LED Choose a Longer Lasting, Better Quality Luminaire For over 100 years, you have been able to depend on Appleton brand products by Emerson for harsh industrial and hazardous locations. We understand that reliability is key to reducing expensive maintenance costs. Our intensive testing program addresses the entire luminaire, including LED driver life, LED lumen depreciation, corrosion resistance in harsh environments, vibration, tolerance, noise and surge immunity, gasket endurance, thermal shock resistance, and more. Only top quality components are used in Appleton luminaires. A Top of Class LED Luminaire The current options of traditional fluorescent, HIDs, and ineffective early generation LEDs are no longer sufficient. You need a longer lasting, better quality luminaire. Mercmaster LED Low Profile Cree LEDs have surpassed 18,000 hours of testing and can report a L70 of over 100,000 hours at +55 C (+131 F). Mercmaster LED Low Profile economic life, which encompasses the entire luminaire performance, can exceed 200,000 hours at +35 C (+95 F). Ambient Temperature Luminaire Life (Hours) Number of Years at 24 Hours Usage +25 C (+77 F) 200,000 23 46 +35 C (+95 F) 200,000 23 46 +40 C (+104 F) 135,000 15 30 +55 C (+131 F) 72,000 8 16 Fixture representative of an MLLED3. Number of Years at 12 Hours Usage Luminaire Maintenance Lumen Maintenance 100 90 80 70 60 50 METAL HALIDE 10,000 20,000 LED HIGH PRESSURE SODIUM 40,000 60,000 80,000 100,000 120,000 10,000 20,000 40,000 60,000 80,000 100,000 120,000 Lifetime (Hours) Ambient (+104 F) to +65 C (+149 F) Ambient Temperature +40 C (+104 F) to +65 C (+149 F) Mercmaster LED Low Profile with Mercmaster II Adapter Appleton Mercmaster II HID Luminaire The photo (right) is a side-by-side comparison of a Mercmaster LED Low Profile (MLLED4J5BU with a Mercmaster II adapter) next to the Mercmaster II 175 Watt Metal Halide luminaire. Consuming only 48 Watts, the Mercmaster LED Low Profile provides equivalent light output with 74% energy savings and no maintenance. 3
HID vs LED Lower your expenses, eliminate relamping time and increase your lighting comfort with the Appleton Mercmaster LED Low Profile Series by Emerson. Energy Comparison Compared to legacy HID luminaires, the Mercmaster LED Low Profile Series saves as much as 74% in energy costs. High Intensity Discharge Luminaires to Mercmaster LED Low Profile Series Energy Comparison HID Lamp (Watts) Mercmaster III Low Profile Series Power Consumption (Watts) Mercmaster LED Low Profile Series Power Consumption Watts 70 MLBG70LMT 94 IMLLED2/MLLED2 28 70% 100 MLBG10LMT 130 IMLLED3/MLLED3 38 71% 150 MLBG15LMT 188 IMLLED4/MLLED4 48 74% % Energy Savings Equivalencies Emerson understands the difficulty in determining equivalent lighting levels with traditional High Pressure Sodium (HPS) and Metal Halide (MH) sources and the adjustments that are needed to factor for Scotopic/Photopic (S/P) ratios. Here are our suggested equivalent lighting range levels for the Mercmaster LED Low Profile. Nominal Lumens HID Equivalent Mounting Height Model Number 3,300 70 to 100 W 6 ft to 12 ft (1.83 m - 3.66 m) IMLLED2/MLLED2 4,400 100 to 150 W 10 ft to 15 ft (3.05 m - 4.57 m) IMLLED3/MLLED3 5,500 150 to 175 W 12 ft to 20 ft (3.66 m - 6.1 m) IMLLED4/MLLED4 Dramatically Reduce Your Lighting Costs Just because your operating budget is low, doesn t mean your expectations have to be. When retrofitting traditional HID task lights, you can quickly achieve break even on your investment. When evaluating lighting systems, consider both the total system power consumption and the expected luminaire life, in order to evaluate energy and maintenance costs and savings. 5 Year Cumulative Luminaire Power Consumption (Watts) Lumen Output Luminaire Efficacy Yearly Energy Costs LED / Lamp Life Annual Maintenance Costs Yearly Fixture Costs Yearly LED Savings Yearly Savings Mercmaster LED Low Profile MLLEDA22CG5BU Mercmaster III Low Profile 70 W MLAL702G1NMT 28 3,300 118 $24.53 109,000 hrs $24.53 94 5,329 57 $82.34 24,000 hrs $60.00 $142.34 $117.81 83% Energy Costs = Watts*24*365*/1000 (Kwh/yr) * $.10/Kwh Maintenance Costs = (24 hours*365 days*5years/24,000 hours*lamp Cost + one ballast replacement)/ 5 years 4
Walkways: Safety is No Accident Achieve a comfortable and safe work environment with uniform light output in low mounting height applications with the Mercmaster LED Low Profile. Walkway lighting is a common application in almost every industry. These heavily trafficked areas must be illuminated evenly and sufficiently to ensure safe passage, especially with regard to changes of direction, level, stairs or any obstructions that may be present. Walkway lighting must also be designed with adequate overhead clearance for safe passage of people and equipment. Additionally, vertical illumination is an important consideration in process areas that require monitoring of instrumentation. The Appleton Mercmaster LED Low Profile luminaires provide: A low profile design to maximize headroom even in confined spaces. A range of lumen outputs from 70 Watt to 175 Watt HID equivalents with multiple interchangeable globe options that enable flexibility of luminaire placement and application. Stanchion and other mounting options to suit any walkway configuration and luminaire height. Rugged, corrosion resistant durability to withstand harsh onshore and offshore environments. Multiple retrofit adapters to avoid re-wiring or changing out mounting hoods minimizing installation costs. 5
Walkway Application Simulation Mercmaster LED Low Profile Luminaires provide similar or better light distribution, better color rendering, and greater lighting uniformity compared to HID luminaires. In walkway applications, they offer the potential to achieve or exceed illumination targets with fewer luminaires, higher mounting heights to reduced wattage luminaires. Simply put, the Mercmaster LED Low Profile is an easy to install retrofit solution that provides comfortable light where you need it, minimizing dark spots and glare for safe working conditions in a compact, lightweight, flexible yet rugged package. Luminaire Sample Application Luminaire Height Type of Mount Luminaire Spacing Targeted Illumination Fc Lux Walkway Mounted at 7 ft (2.13 m) 25 Stanchion 18 ft (5.5 m) 5.00 53.82 Mercmaster III Low Profile 70 W MLSL704G1NMT Mercmaster LED Low Profile MLLED2CJ5BU 1.00 FC (10 Lux) 2.00 FC (20 Lux) 3.00 FC (30 Lux) 5.00 FC (50 Lux) 8.00 FC (80 Lux) 10.00 FC (100 Lux) 15.00 FC (150 Lux) 20.00 FC (200 Lux) Traditional walkways often use 70 watt HPS luminaires. The simulation on the left shows the light distribution of a legacy Mercmaster III Low Profile HID Luminaire. Compare that to the simulation on the right which shows that same walkway with a one-to-one retrofit using the Mercmaster LED Low Profile Luminaire. The Mercmaster LED Low Profile Luminaire creates a more comfortable and even light distribution, meets light levels and uniformity requirements, reduces installation and power expenses, and saves 66 Watt per fixture over traditional Mercmaster III 70 Watt HPS. Lighting Performance Luminaire Power Consumption (Watts) Light Output (Lumens) Eav Floor Emin Floor Emax Floor Fc Lux Fc Lux Fc Lux 70 W HPS 94 4704 17.00 183.00 9.05 97.41 29.00 312.15.315 MLLED2CJ5BU 28 3020 9.36 100.75 4.47 48.11 16.00 172.22.286 Emin/Emax 6
Pipe Racks: Maximize Light with Minimal Profile Deliver Safe, Efficient and Comfortable Lighting to Hazardous Locations Throughout Your Facility with One Versatile Luminaire Areas under pipe racks need effective, comfortable lighting for worker safety and productivity. The interchangeable globes of the Mercmaster LED Low Profile ensures that the light distribution desired can be achieved. To maximize light on the ground, choose the clear polycarbonate or glass globe, but if a more comfortable light that minimizes glare is what you require, use the prismatic glass refractor or diffused polycarbonate globe. The rugged and corrosion-resistant Mercmaster LED Low Profile Luminaires are certified for Class I, Division 2 Groups A, B, C, D; Class I, Zone 2, Group IIC; Class II, Division 1, Groups E, F, G; Zone 21, Group IIIC; and Class III hazardous locations. They are also rated for use in marine and wet locations, and hold global ATEX/IECEx Zone 2, 21 and 22 certifications making them an easy choice for a wide variety of industries and pipe rack applications. 7
Pipe Rack Application Simulation Pipe racks can be found in most industrial and hazardous location facilities and require safe and comfortable lighting to ensure worker safety. Luminaire weight and profile may be a consideration when designing and maintaining lighting for pipe rack applications. The lighter the fixture, the less dead weight the pipe racks must hold. Luminaire Sample Application Luminaire Height Type of Mount Luminaire Spacing Targeted Illumination Fc Lux Pipe Rack Mounted at 4.27 m (14 ) Ceiling/Pendant 6.1 m (20 ft) 5 50 The application above shows that the Mercmaster LED Low Profile 4000 lumen luminaire with the diffused polycarbonate globe (MLLED3CD5BU) meets the 5 Footcandle illumination target and saves 92 Watt per fixture over traditional 100 Watts HPS. The Mercmaster LED Low Profile provides a closer targeted illumination average with fewer hot spots and more comfortable light output. Performance Comparison Luminaire Power Consumption (Watts) Lumen Output (Lumens) NEMA Pattern Average Illuminance Maximum Illuminance Minimum Illuminance FC Lux FC Lux FC Lux 100 W HPS 130 6512 Type V 7.41 79.76 9.12 98.17 5.17 55.65.567 MLLED3CD5 38 4151 Type V 5.94 63.94 7.42 79.87 3.77 40.58.508 Uniformity (EMIN/EMAX) Wattage Reduction (%) 71 Energy Savings LED luminaires provide far greater lighting efficacy compared to traditional lighting sources. Savings of over 70% can be achieved simply by retrofitting with LED. Maintenance Savings Metal Halide lamps last an average of 20,000 hours, or 2.28 years, in continuous use. By contrast, LED luminaires are typically rated for 60,000 hours and can exceed 200,000 hours depending on ambient temperature. With LED luminaires you can install it and essentially forget it. Safety LED luminaires provide instant on and cold-start capabilities without end-of-life degradation or premature failures due to frequent cycling providing a safer work environment particularly in extreme temperatures. And the solid state (no moving parts) nature of the luminaire is perfect for high vibration work environments such as oil rigs. 8
Mercmaster LED Low Profile Luminaire Specifications 9 IMLLED2 and MLLED2 IMLLED3 and MLLED3 IMLLED4 and MLLED4 Equivalent to HPS/PSMH 70-100 Watt 100-150 Watt 150-175 Watt Input Power 28 Watt 38 Watt 48 Watt 120-277 Vac, 50/60 Hz, 120-277 Vac, 50/60 Hz, 120-277 Vac, 50/60 Hz, 170- BU Voltage Range 170-300 Vdc 170-300 Vdc 300 Vdc BH 347-480 Vac, 50/60 Hz 347-480 Vac, 50/60 Hz 347-480 Vac, 50/60 Hz NEMA Type V Diffused Polycarbonate Globe (3100) 111 4100 (108) 5150 (107) NEMA Type V Glass Globe 3300 (118) 4400 (116) 5500 (115) NEMA Type V Glass Refractor 3000 (107) 4000 (105) 5000 (104) Correlated Color Temperature (CCT) 3000K/4000K/5000K 3000K/4000K/5000K 3000K/4000K/5000K Color Rendering Index (CRI) 70 70 70 Ambient Temperature 40 C ( 40 F) to +65 C (+149 F)" NEC/CEC Certifications Hazardous Location Class I, Division 2, Groups A, B, C, D Class I, Zone 2, Group IIC Class II, Division 1, Groups E, F, G Zone 21, Group IIIC Class II, Division 2, Groups F, G Class III Type 3R, 4, 4X IP66/IP67 Simultaneous Exposure Suitable for Use in Wet Locations Marine Outside Type (Salt Water) For USA ONLY CSA Master Contract 164460; Certificate Number 70134063 40 C ( 40 F) to +65 C (+149 F)" 40 C ( 40 F) to +65 C (+149 F)" T Rating (NEC/CEC) Class I, Division 2 T4A @ +65 C (+149 F) T4A @ +65 C (+149 F) T4 @ +65 C (+149 F) T Rating (ATEX/IECEx) Zone 2 MLLED2 T4 @ +65 C (+149 F) MLLED3 T4 @ +65 C (+149 F) MLLED4 T4 @ +65 C (+149 F) Luminaire Weight 4.6 kg (10.1 lb) 4.6 kg (10.1 lb) 4.6 kg (10.1 lb) Mounting hoods and bodies: cast copperfree (4/10 of 1% max.) aluminum Gaskets: silicone All hardware and catch assemblies: stainless steel Globe: polycarbonate or glass Standard Materials Refractor: heat-resistant prismatic glass Glass globe guard and safety cable: stainless steel wire Glass refractor guard: die cast aluminum Mounting hoods, bodies and glass refractor guard: gray epoxy powder coat finish, electrostatically applied for complete uniform protection >100,000 hours @ +40 C (+104 F) ambient temperature Lifetime >60,000 hours @ +65 C (+149 F) ambient temperature Warranty 5 years standard BH voltage only permitted for ccsaus rating. All values typical +/-10%. 154.4 (6.08) 339.7 (13.37) Driver Housing with globe *Refer to ambient range table which is contained in the IECEx certificate of conformity file or the catalog pages for T-code ratings. ATEX/IECEx Certifications and Compliances Hazardous Location Certification Type: Mercmaster Low Profile Gas: Zones 2 Conforming to ATEX 2014/34/EU: II 3 G Type of Protection: Ex ec IIC T* Gc Temperature Class: T5 to T4 Dust: Zones 21 and 22 Conforming to ATEX 2014/34/EU: II 2 D Type of Protection: Ex op is tb IIIC T* C Db Ex tc IIIC T* C Dc Surface Temperature: +66 C to +88 C (+151 F to +190 F) Ambient Temperature: -40 C up to +65 C (-40 F up to +149 F) ATEX Certificate: Sira 17ATEX9365X IECEx Certificate: IECEx SIR 17.0085X Index of Protection according EN/IEC 60529: IP66 Impact Resistance (shock): IK08 Photobiological Safety, IEC 62778 and IEC 62471: Pending
Don t Compromise on How and Where You Hang Fixtures Mounting Hoods and Accessories The Mercmaster LED Low Profile s larger variety of mounting hoods and accessories means you can hang your luminaires how and where you need them. You no longer have to compromise on fixture placement; wall, pendant, ceiling, and stanchion choices are available to make installing lighting around cabling, pipes and process equipment as easy as possible. Plus, with accessories like glass and polycarbonate globes, guards, visor, and safety cables, the Mercmaster LED Low Profile offers specific solutions for all your tough application challenges. Pendant - KPA Pendant Cone - KPCH Ceiling - KPC Wall - KPWB 25 Stanchion - KPS 90 Stanchion - KPST Accessories Globes and Gaskets Description Globe Guards and Safety Chain Description Clear Globe (polycarbonate) VPGL-LED Glass Globe Guard MGU1 Diffused Globe (polycarbonate) VPGL-DIFF Refractor Guard KRG2 Glass Globe Clear VPGL-GLASS Safety Cable LEDSC Glass Refractor NEMA Type V Light Distribution LPG-R5 Standard Adapters for Retrofits MMADCHVS (Crouse-Hinds ) MMADIIS (Mercmaster II) Offset Adapters for Retrofits MMADCHVA (Crouse-Hinds ) MMADIIA (Mercmaster II) Visor MMVISOR NEMA Type V glass refractor only permitted for ccsaus rating. 10
Maximize usable light enabling you to comfortably and safely work in harsh or hazardous environments. Appleton is the cornerstone brands of Emerson's Electrical Apparatus and Lighting business; trusted worldwide to make electrical installations safer, more productive and more reliable. United States (Headquarters) Appleton Grp LLC 9377 W. Higgins Road Rosemont, IL 60018 United States T +1 800 621 1506 Europe ATX SAS Espace Industriel Nord 35, rue André Durouchez, CS 98017 80084 Amiens Cedex 2, France T +33 3 2254 1390 Canada EGS Electrical Group Canada Ltd. 99 Union Street Elmira ON, N3B 3L7 Canada T +1 888 765 2226 Asia Pacific EGS Private Ltd. Block 4008, Ang Mo Kio Ave 10, #04-16 TechPlace 1, Singapore 569625 T +65 6556 1100 Latin America EGS Comercializadora Mexico S de RL de CV Calle 10 N 145 Piso 3 Col. San Pedro de los Pinos Del. Álvaro Obregon Ciudad de México. 01180 T +52 55 5809 5049 Australia Sales Office Bayswater, Victoria T +61 3 9721 0348 China Sales Office Shanghai T +86 21 3338 7000 Middle East Sales Office Dammam, Saudi Arabia T +966 13 510 3702 Chile Sales Office Las Condes T +56 2928 4819 India Sales Office Chennai T +91 44 3919 7300 Korea Sales Office Seoul T +82 2 3483 1555 Emerson.com LinkedIn.com/company/emerson The Emerson logo is a trademark and service mark of Emerson Electric Co. Appleton is a registered trademark of Appleton Grp LLC. All other marks are the property of their respective owners. 2018 Emerson Electric Co. All rights reserved.