6 tips for extending the service life of your LED luminaire

LED light sources last up to 100,000 hours or over 25 years in normal operation. In theory. However, a number of influences can drastically shorten the service life of LEDs.

Particularly in industrial applications, lights need to function reliably under demanding conditions. What should you pay attention to when buying, installing and operating your LED luminaires in order to maximise their service life?

Tip 1: Only buy high-quality luminaires with integrated protective functions

It may sound obvious, but a high-quality, stable LED luminaire lasts longer than an inferior one. Nevertheless, luminaires for professional use are often bought purely on the basis of price – and then break relatively quickly.

For this reason, we have integrated a protection concept into all our LED2WORK luminaires that neutralises the two biggest enemies of an LED luminaire: fluctuations in power supply and high temperatures.

Electrical protection

• The suppressor diode or transient voltage suppressor (TVS) prevents voltage peaks in the supply power from destroying the lamp. Peaks like these occur, for example, when major consumers in the power grid (such as welding robots) are switched on and off.
• An inline diode is used for reverse polarity protection. It prevents current from flowing “backwards” through the luminaire due to incorrect polarity – which would otherwise destroy the LED lamps.
• The linear regulator makes sure that the lamps always receive exactly the current they are designed for – regardless of fluctuations in the power grid.

Heat dissipation

• The housing of our luminaires acts as a heat sink: thanks to its aluminum construction, it conducts the heat from the LED lamps in the best possible way and releases it into the environment. The temperatures inside the luminaire remain within the normal range.

Tip 2: Choose luminaires to suit the area of application and ambient conditions

Even the best luminaire will give up quickly if operated under conditions it is not designed for. A workplace light for an assembly table is not suitable for operation in a machine where it comes into contact with lubricants and is exposed to vibrations.

You should therefore choose luminaires designed specifically for the purpose and process they are involved in. The technical specifications of a luminaire provide information on this:

• Protection rating (IP class): Depending on the ambient conditions, such as moisture, dirt or chemicals, luminaires with an appropriate protection rating are needed. This ranges from IP20 (no protection against moisture and foreign bodies) to IP69K (protection against high temperatures and high-pressure/steam jet cleaning).
• Impact resistance (IK class): In environments exposed to shocks or vibrations, impact-resistant and shock-proof lights are required. The IK classes provide information about mechanical strength, with IK10 representing the highest level.
• Temperature range: Make sure that the lights are suitable for the intended temperature range, for example, when installing them in machines that generate a lot of heat or in cooling areas.

Furthermore, luminaires should not be misused: for instance, surface-mounted luminaires are usually not ideal for recessed installation. If you are unsure, simply ask the manufacturer which luminaire is the best choice for your requirements.

Tip 3: Install LED lights in a clever position

Next, you can extend the service life of your LED lights by choosing the best possible installation position:

• Make sure that the luminaire can dissipate heat to the surroundings. Either install the luminaire so that the air can circulate around the outside, or so that it is in contact with metal or other highly conductive materials.
• Do not place LED lights near other heat sources or in such a way that they are surrounded by highly insulating materials. If there is no other option, opt for a luminaire that can withstand the higher temperatures in the long term.
• Position luminaires in such a way that they are exposed to as little moisture, dirt or chemicals as possible.

Our luminaires are deliberately designed for use in harsh industrial conditions, and the housings (of luminaires with higher protection classes) are sealed and robust. However, the luminaires should not be operated continuously within the absolute limit range if they are to have a long service life. Even small adjustments to installation position can often significantly reduce the load.

Tip 4: Ensure a stable power supply

LED luminaires require a stable DC voltage power supply. When subject to ongoing, severe fluctuations, luminaires can break down within weeks.

Aren’t the protective devices mentioned above, such as suppressor diodes and linear regulators, intended to protect against this? Yes, and they do – but only to a limited extent. They can cope with the usual dynamics in the power grid. But under high and constant load, the protective devices get broken.

You can prevent this by taking two measures:

• Do not use older transformers or rectifiers without smoothing in your installations, but only devices with protection class III (recognizable by the “III” symbol), Power Factor Correction (PFC) and sufficient SURGE interference immunity.
• Avoid voltage peaks in the supply line. Check the power supply for sources of interference and install protective devices such as varistors or surge arresters if necessary.

If the supply voltage is too low, the protective devices will not help either. This can occur in particular when cascading multiple lights. The cable lengths and cross-sections must be sized such that the last light in the row is still supplied with the required voltage (24 V with a tolerance of 10%).

Tip 5: Clean the luminaires regularly

LED luminaires are practically maintenance-free. You only need to remember to clean them regularly. It is best to explicitly include the luminaires in your cleaning plans so that they are not overlooked.

Simply wipe the luminaires with a damp cloth. This prevents dust, dirt or residues from oils and coolants from settling on the surfaces. Deposits of this kind can burn into the glass over time and “swallow” the light.

Tip 6: Have faulty luminaires repaired instead of throwing them away

Our LED luminaires are extremely reliable: complaints are only made for 0.03% (3 out of 10,000) of all luminaires. If a light source does fail or your luminaire is damaged, there is no need to dispose of it. Send us the luminaire and we will repair it if possible. This is not only cheaper, but also better for the environment.

Conclusion: Service life is crucial for economic efficiency

In the long term, the price of a luminaire has hardly any influence on the efficiency of the lighting. Whether your luminaires last 2 months, 2 years or 20 years has a much greater impact. In addition, long-lasting LED luminaires save you a lot of work and hassle. Broken luminaires impair work processes and can cause errors and accidents. By having high-quality, durable luminaires that are installed correctly, you do your budget and your employees a favour.