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Energy efficiency all under control

In seeking a reliable and robust light solution for its expansive manufacturing and storage facility, global energy management specialist, Schneider Electric knew there was only one product to fit the bill – its very own C Bus system.

In seeking a reliable and robust light solution for its expansive manufacturing and storage facility, global energy management specialist, Schneider Electric knew there was only one product to fit the bill – its very own C Bus system

Highly reputed in the industrial and commercial arena, C-Bus lighting control solutions combine controls, sensors and flexible user interfaces to provide automated control of lighting based on occupancy and ambient light levels.

As the first step of the installation, a total of 330 metal halide high bay fittings were replaced with DALI T5 dimmable luminaires. These energy-efficient alternatives enable full dimming control, from 100 per cent to zero and any value in between, and also provide luminaire performance data including lamp, power and ballast status.

Subsequently, Schneider Electric installed its innovative Clipsal Schedule Plus software, a simple yet powerful control and monitoring solution. This has allowed automated lighting to be based around shift patterns, so that at the end of each shift the fittings in that area will start a ramp down to a zero program, lasting around five minutes. In case people may still be working there is even a one hour over-ride option, triggered by local switchers on the production floor which are mounted within a steel enclosure to avoid nuisance switching.

Optimum maintenance is achieved through the use of lux level sensors measuring the combined light output of the fittings with the amount of natural light coming through the skylights. This not only ensures a consistent lighting level is maintained, but it also means if a tube or fitting fails then the surrounding fittings will increase output to compensate.

To finalise the installation, PIRS have been applied throughout walkway areas of the building. While this area was previously continuously illuminated, it is now set up so if there are no occupants the fittings will reduce to just 10 per cent.

Upon completion of the installation, the business and environmental benefits for Schneider Electric seem unlimited. On average, through enabling strategic dimming to be deployed throughout a property, DALI lighting can help to achieve energy savings of 30 to 60 per cent.

Plus, while lighting levels with discharge lighting were previously 100 lux at eighteen metres, this has now been increased to greater than 400 lux at eighteen metres, reducing the need for localised task light. This increase has added further energy saving benefit.

Another advantage is reduced servicing, as T5 lamps require less maintenance and have a longer service life. Overall, the project is expected to see a return on investment in as little as 30 months.

Looking ahead, the Schedule Plus software means the lighting levels can be continually adjusted to match the demands of the manufacturing processes being used on site. Free Firmware updates ensure the system is always up-to-date to take advantage of new developments of the system, as well as the changing technologies of the lighting manufacturers.

Chris Stapylton, Health, Safety & Environment Manger at Schneider Electric said “As a business committed to spearheading sustainability here in the
UK, we are always looking for ways to maximise our own productivity and efficiency.

“As such, following a consultation, we felt it was important to make adjustments to our large manufacturing facility, which covers 17,000 sq metres. As our C Bus system is an extraordinary product, specifically designed to meet the ever-complex energy requirements of industrial and commercial buildings, it was therefore the obvious choice.

“Overall, the project has been very successful and we are already starting to see reduced running costs, both in terms of energy saving and reduced maintenance. We’re now considering future projects for the building, which we will be looking to progress within the next six months which include expansion of the C-Bus controls for the switching of office lighting. We also plan to replace fixed drive compressors to a variable speed drive option; surveys undertaken by suppliers have indicated savings of 12k per annum in power consumption through the optimisation of load and off load energy, payback on this project is expected to be less than 24 months.”

Future site improvements will include; automatic powerlogic meter readings using the ERM monitoring package, comprehensive CCTV security system using Pelco and Full Building Management System with the inclusion of C Bus lighting control.

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