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Canopy Lighting: Value that is Clearly Visible

Meredith Anderson reports on the recent changes in canopy luminaire (fixture) technology and design that are brightening the profitability of retail service stations today (part two).



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Author: Anderson Meredith
Luminaires that make sense and cents
In Part One of this two-part series (“Canopy Lighting Technology: Don’t Be in the Dark,” May, page 18), the evolution of canopy lighting and lamp (light bulb) technology was highlighted. Part Two sheds light on recent changes in canopy luminaire (fixture) technology and design that have brought cost savings and added value to the light that leads the way to pumps and C-stores.
Photo 1—Canopy accent lighting used to highlight corporate colors with red LEDs along the lower edge of a canopy fascia. Courtesy of Jet-Phillips Lighting, Inc.

In the petroleum marketing industry, “change” is good, especially when it comes in the form of coins that add up to dollars that wend their way into owners’ pocketbooks. Over the course of the past five years, sweeping changes in luminaire design and technology offer bottom-line bargains that shed light more effectively.

A luminaire (see Photo 2) is a complete lighting unit made up of a lamp (“light bulb”) and ballast together with the parts designed to 1) distribute the light, 2) position and protect the light source and 3) connect the light source to the power supply. Metal halide lamps are, by far, the lamp of choice for canopy lighting. A ballast is a device used with a metal halide lamp to obtain the necessary circuit conditions (voltage, current and waveform) for starting and operating. The housing encloses the fixture and provides a structure for all the lighting elements. The lens (or refractor) is a glass or plastic element used to change the direction and control the distribution of light rays. The reflector is a also device used to redirect the light. Shielding reduces glare for safety and lessens light trespass (light going beyond property lines).

 
 
Photo 2—Cross-section of a the latest, enhanced version of the Scottsdale luminaire first introduced in 1995. The ballast housing is contained within the canopy structure (blue background); the lamp and optical elements are located underneath the canopy deck (white background). Patents No. D375,379 and 5,662,407. Courtesy of LSI Industries Inc.

Time for a change
By the beginning of the 1990s, a plateau in luminaire design left lighting consumers with little more than pricing as the major variable in a lighting purchase. Though competition tended to drive the initial cost down, the long-term expense of lighting drained dollars from owners’ bottom lines.

Canopy luminaire options consisted of surface mount or recessed luminaires. The square surface mount luminaires, which dropped below the canopy deck, were relatively large (typically 2 ft.x 2 ft. x 10–12 inches). Recessed fixtures typically directed lighting onto horizontal surfaces, leaving dispensers poorly lit.

The relatively large traditional metal halide lamps mounted in these fixtures were oriented in a horizontal plane and aged quickly. To compensate for the dropoff in lumen output over time, stations owners were forced to overlight canopies initially. Color instability in aging lamps produced an unintended rainbow of pink and blue hues.

Heat generated by a high-wattage lamp took a toll on components housed centrally within the fixture. The ballast aged and, at maximum, carried a two-year warranty. In some cases, the lens (usually constructed of acrylic or plastic) cracked and yellowed in the presence of both the heat and ultraviolet light over time. Dirt and bugs entered through cracks in the lens, further reducing lens effectiveness.

Time-consuming installation and maintenance of lamps and luminaires also took a toll on owners’ pocketbooks. Canopy heights dictated that specialized service companies with either a bucket-truck or scaffolding not only change lamps, but clean reflectors and refractors.

Though some attempts were made to address these costs—such as encouraging owners to re-lamp rather than continuing to use aging, dimming and inefficient (and, thus, more costly to use) lamps, and improving the lighting results by lighting vertical surfaces—canopy lighting needed to change.

A new direction
Trapped in a market tied to pricing with little variation in products offered, LSI Industries Inc., under the leadership of CEO Robert (Bob) Ready, undertook the development of a new luminaire, one that would take into account all of the needs unique to a petroleum retail refueling facility. With an emphasis on the total cost of ownership and the marketing function of lighting, the LSI team set their sights on a new horizon.

The redesign effort led to synergistic changes. Specifications developed by LSI addressed cost elements that owners faced and, when assembled into one package, solutions spun off additional advantages.

The new luminaire, christened the “Scottsdale,” offered the advantages of:

1) lower operating costs;
2) an increased life span of components;
3) a redesigned metal halide lamp;
4) a distinctive, aesthetically-appealing appearance; and
5) easier installation and maintainance.

Major re-designs included:

• Component compartmentalization—Removing the ballast unit from the central housing away from the lamp and socket reduced the amount of heat to which the ballast was exposed (see Photo 2). With every 10-degree reduction in temperature, ballast life could double. The ballast warranty was extended from two to five years, a long-term savings to owners. By placing the ballast within the canopy structure, the optical unit was dramatically reduced in size; both an aesthetic and, ultimately, a cost benefit.
• Vertical “base up” orientation of the lamp within a drop lens—With the tip of the lamp now extending downward, more light was now visible directly beneath the canopy as a vertically lit surface. This signaled to motorists “We’re open for business.” Furthermore, canopy light no longer only directed downward, and could light the way through the “valley of darkness” from the canopy to the convenience store. Wattages could be reduced with lighting levels maintained over time because arc tubes did not age as rapidly.
• Pulse start lamp technology—Removal of the starter probe from the lamp and the replacement with an ignitor within the ballast introduced the pulse start technology into metal halide lamps. This, together with other changes to the lamp design, resulted in a 320-watt, pulse start metal halide lamp that, ultimately, has offered more lumens per watt, better lumen maintenance over time, greater color stability and a longer lamp life.
• Prismatic glass lens—Substitution of glass for acrylics or plastic offered multiple advantages. Glass did not age and was easily cleaned and maintained. Faceted, (as opposed to flat glass) surfaces added sparkle and directionality to the light. Light could now be directed to the canopy deck and vertical surfaces, such as the dispenser face, on which corporate colors could effectively be displayed.
• Ease of installation and maintenance—With redesign, easier installation required less personnel and equipment. Drilling large holes and the time-consuming attachment of the fixture to the canopy deck was no longer necessary. A small four-inch hole could be drilled to accommodate the ballast box placement from above and the low-profile optic assembly suspended from below. A new latch, combined with a “re-lamping stick,” provided a means to change lamps from the ground and, thus, saved the expense of specialized maintenance equipment or crews. With ground access, changing lamps could also be done when needed to avoid the declining lumen output of aging lamps.

Since 1995, LSI Industries Inc. has further refined the Scottsdale luminaire, offering upgrades that have enhanced performance and provided value for consumers.

Whiteway Division of Spaulding Lighting, Inc., a manufacturer of canopy lighting since the mid-century mark, recently launched its Galasy luminaire. Whiteway designers have incorporated successful time- and money-saving features, such as the separation of components, a low-profile luminaire with a vertically oriented lamp, optical directionality within the refractor and ground re-lamping (see Photos 3-5). Though metal halide lamps from 250 watts through 400 watts can be used, the unit was designed specifically as a 400-watt fixture. A fiberglass-reinforced bezel surrounds the frameless optical lens, reduces glare and, as an option, can be color-coordinated. The intensity of light can be softened with diffuser options and reflector configurations changed for desired directionality.

Photo 3 to 5:
Ground re-lamping using a “re-lamping stick” provides petroleum retail operations with a means of changing lamps that does not require specialists or specialized equipment. Photos 3 through 8, courtesy of Whiteway Division, Spaulding Lighting, Inc.
 
 
 
 

Prism cuts of the glass refractor direct light along the main beam at a 40 degree angle to highlight vertical surfaces (see Diagram 1). From the nadir (0 degrees) to 40 degrees, prism cuts spread the beam both horizontally and vertically. Light beams that emerge at angles from 80-85 degrees to 90 degrees are directed upwards to light the canopy surface. To avoid possible glare, prism cuts are made to redirect the light beams from above 40 degrees and under 80 degrees to either the 40 degree angle or above 80-85 degrees. Notable design features ease installation. Once a four-inch circular hole is drilled in the canopy deck, installation of the luminaire can continue without tools. Ballast boxes are placed on cross brackets suspended from the canopy ribs, thus transferring the weight of the luminaire onto the canopy structure rather than the deck pan (see Photo 6). Once the ballast boxes are centered over installation holes from above, the installer can move beneath the canopy to fit the assembled optical unit with its vertical brackets into the ballast receiver assembly (see Photo 7). Using moderate force, the installer pushes the unit upward until it clicks into place. A cam action disc in the ballast assembly seals the installation (see Photo 8).

Note: Light beams redirected to 40º and above 80º–85º in circled area
 
Diagram 1: Refractor prism vertical performance distributions for the Galasy luminaire. Courtesy of Whiteway Division, Spaulding Lighting, Inc.
Photo 6:
Ballast box placement above the canopy deck for installation.
Photo 7:
Installation of the assembled optical unit with its vertical brackets into the ballast receiver assembly from below the canopy.
Photo 8:
A cam action disc in the ballast assembly seals the installation and completes the tool-less installation of the luminaire.

Ease of installation for electricians was also engineered into the Galasy. The lamp socket is designed into the ballast housing, eliminating the need to pull socket wires. The receiver for electrical conduit is also of tool-less design. The only wiring required is to the power source. For electricians who like to loop their wiring canopy light to canopy light, entry holes on either side of the unit provide a wireway.

To a large degree, all luminaire manufacturers have benefited from the technological and design advances of the last five years. Owners simply cannot afford to ignore the cost savings available to them through a range of products, including updated versions of traditional “two by two” luminaires that offer inherently side-shielded products without undesirable glare (see Photo 9).

Photo 9:
Updated version of the “two by two” luminaires dominated in canopy lighting prior to the mid-1990s. Courtesy of Spero Electric Corporation.

In addition, owners not yet ready for a “rehab” can retrofit traditional two-by-two surface-mount luminaires, using kits (available from LSI Industries Inc. or Spaulding Lighting Inc.) that incorporate cost-sparing lamp and ballast advances. Bottom line—good canopy lighting makes good business sense.

 

 

What exactly is “good” lighting?
Ask ten people in the lighting industry what “good” lighting is and you will probably hear ten answers, each with a unique perspective.

At the heart of any lighting concern is meeting consumers’ expectations for a clean, well-lit environment in which they feel safe. One study that has looked at perceptions of security was conducted by Peter Boyce, PhD, who heads the Human Factors Program of the Lighting Research Center at Rensselaer Polytechnic Institute. The project was an outgrowth of research included in a book, The Outdoor Lighting Pattern Book, co-authored by Professor Russell Leslie, AIA, FIES, LC, and Paula Rodgers, IES. “The study was really answering the question of how much light is needed for a sense of security,” says Professor Leslie, Associate Director, Lighting Research Center.

Study subjects were driven through ten outdoor sites in New York City and ten outdoor sites in suburban Albany, New York. Before the subjects visited the sites, researchers measured light levels of vertical and horizontal illumination. The subjects were asked questions such as “Is this an example of good security lighting?” Their responses were then correlated to the different light levels.

“The result is that, quite convincingly, people rated the different sites—some well-lit and some poorly lit—higher with higher levels of illuminence; results in both the urban and suburban settings are consistent,” says Professor Leslie. “Somewhere around three footcandles* on the horizontal surfaces, this effect begins to tail off rapidly. Thus, while there was an improvement in the feeling of security up to about three footcandles, thereafter there was only a slight increase. Thus, the gain in perceptions of safety between five and 10 footcandles* is almost insignificant.”

*Footcandle is a unit of measure of the intensity of light falling on a surface, equal to one lumen per square foot and originally defined with reference to a standardized candle burning at one foot from a given surface.

Beyond the perception of security, lighting levels move into the realm of retailing. Good canopy lighting is just one among many lighting considerations in a retailing facility. Lighting design for a refueling center should be approached holistically, looking at the entire site—the canopy, the parking areas, the convenience store and the landscape. Marketing objectives—lighting what owners want to sell or what they want the customers to see—should be considered when determining lighting levels for a retailing environment.

Overlighting a canopy may come at the expense of the convenience store. “If you achieve a lighting level of 100 footcandles under the canopy and 60-90 footcandles in the C-store, the C-store may appear dark and dingy by comparison,” says Keith Kondrot, RA, architect and Principal of STREETSCAPE Architects.

Performance, ultimately, is a key consideration when evaluating fixtures for multiple locations in the case of larger operations such as a major oil company. Assessing the total cost of lighting is critical. To do so, evaluate performance characteristics—lumen output, footcandles at a certain mounting height, the amount of vertical as opposed to horizontal footcandles and wattage—of fixtures within a manufacturer’s line. Then compare performance characteristics of product lines from manufacturer to manufacturer. A particular fixture might cost more initially, but the performance characteristics may actually reduce the number of fixtures needed; thus saving money in the long run.

For an independent marketer with fewer numbers of facilities, lighting can be more site specific. An invaluable resource for specific sites are lighting consultations available as a service through lighting companies.

For Terry Baker, Sales Manager of the Petroleum Division of Spero Lighting, good lighting is driven by the science of illumination that takes into account the totality of marketing, aesthetics, productivity, installation and maintenance. Good lighting is comfortable for the viewer and evenly distributed without glare.

“Three types of glare are possible when lights are too bright,” says Nancy Clanton, PE, IALD, a lighting designer and engineer of Clanton & Associates. “Disability glare causes the eye to shut down in order to protect itself; you can’t see details. Discomfort glare, often experienced by the elderly, occurs when brightness actually causes pain. Annoyance glare results when noxious light invades property lines and creates never-ending brightness.

“Brightness can have a negative impact on the eye’s night-time adaptation to differing light levels. Going from low-light to high-light levels is a simple adaptation. But, going from high- to low-light levels introduces a time element in which your eye has to re-adapt to the lower lighting levels. With aging, the eyes adapt less well and take longer to do so; particles within the eyes may scatter light.”

Good lighting, according to Nancy Clanton, takes the surrounding community into account. “You need to look at the environment—the topography and ambient light. For example, one new service station in Eagle, Colorado, was located near the interstate at an elevation higher than that of the community; its lights flooded town residents from above. The town paid to have the service station relamped. We then helped to write lighting ordinances that were equipment-based rather than based on light levels.”

One resource for exploring good outdoor lighting is now available. The IESNA Outdoor Environmental Committee, which Nancy Clanton chairs, recently completed an update of Recommended Practices 33, Lighting for Exterior Environments. The document addresses “good responsible outdoor light,” guides municipalities seeking to write lighting ordinances and recommends canopy lighting levels. “Canopy lighting can be designed well by eliminating glare, lighting just what you need, lighting more vertical surfaces and lowering the brightness of the luminaire itself. By doing this, canopy lighting can have lower energy usage with more neighborhood appeal,” Nancy Clanton observes.

“Furthermore, when leaving the canopy to darker roadways, transition problems that result from these changes in lighting levels can be minimized if lighting levels meet IESNA RP-33.”

To help determine lighting levels and plan luminaire purchases, lighting customers can tap into a no-cost lighting assessment that is offered by all major lighting companies. The process involves providing the lighting consultant with a site plan. A point by point layout is then computer-generated in which the lighting levels throughout the property are plotted. Lighting consultants advise customers of options, in many cases assigning dollar amounts for comparison.

“For example,” says Terry Baker, “it’s possible to save $33 per fixture per year by using a 320-watt metal halide pulse start lamp versus a comparable 400-watt lamp, based on a 12-hour burn cycle at eight cents per kilowatt hour.”

Before
  
After
 
 
Photos 10 and 11: This Maxicon fascia lighting system, which uses high-wattage floodlights located away from the canopy, projects light onto canopy fascia. The location of the floodlights must be precise to avoid glare. Shown are before (left) and after the installation of floodlights. Courtesy of Jet-Phillips Lighting, Inc.

Location, location, location
Location definitely affects lighting levels. In a highly commercialized urban setting, higher lighting levels may be more acceptable than in residential neighborhoods where lighting levels can become an issue of light trespass, the spill of light beyond property lines. To avoid the expense of having a project die in the planning process, architects or certified lighting designers familiar with lighting issues can be of service to lighting consumers planning canopy lighting.

Each year, Keith Kondrot is involved with approximately 100 service station projects for major oil companies, jobbers and petroleum dealers. Eighty percent of these projects do not survive the site development stage. Of the remaining 20 projects, he guides clients through the permitting process and stops along the way—the building department, code enforcement, the zoning board of appeals and village or city boards. Because a project can be halted at any step of the way, he must be aware of codes and standards, including those that address lighting, for the communities in which the proposed facilities are to be built.

“Canopy lighting becomes a matter of balancing what marketers want and what the city will allow,” says Keith Kondrot. “Brightness, particularly at night, tends to make a site look cleaner, brighter and alive. More important, you have a commercial site that has high traffic through it, especially when it comes to driveways. You have real life safety issues—of pedestrians walking, people driving vehicles on and off the property. The retail refueling station should be well-lit and well-maintained from a lighting standpoint.

“Typically, lighting standards along property lines are one footcandle. Some communities are adamant about levels of 1/10 of a footcandle at the property line. These standards are difficult to meet when adding a canopy to a small, existing facility or doing a ‘raze-and-rebuild.’ You simply don’t have the ‘yard’ to develop. When owners buy a brand new site, they may be obliged to buy 15 more feet in either direction to enable canopy lighting to dissipate to avoid lightspill at the property line. As an architect, I have to deal with what are called ‘N.I.M.B.Y.’ city planners. Gasoline stations are viewed as Not In My Back Yard. Everyone wants and needs them, just not in their backyard.

“About 10 percent of the communities that I deal with have stringent lighting standards. Communities are becoming more sophisticated in terms of lighting. Maybe within a decade, that number will be closer to 50 percent. In metro areas, it’s a growing trend.”

Even after surviving the stage of planning and zoning, canopy lighting can cost more money for owners if objections to light trespass, either into surrounding residential properties or roadways, mandate changes. Because lamps and ballasts must be matched, changing to lower wattage lamps means similar changes in ballasts—not an inexpensive proposition. To avoid either glare or light trespass, lighting manufacturers now offer alternate reflector configurations and side shields or diffusors for luminaires.

Indirect and accent lighting
In recent years, indirect and accent lighting on canopies have served marketers’ needs to highlight corporate colors and even the canopy itself. Though high-out put fluorescent lamps have been widely used, the drawbacks of dimming in cold weather or “hard” starts with high humidity—as well as notable energy consumption and maintenance requirements—have stimulated interest in other options.

The obvious drama of an indirectly lit canopy is apparent in the “before” and “after” Photos 10 and 11; however, floodlighting used at the angles needed to achieve this effect must be highly controlled to avoid glare. One such floodlighting system (see Photo 12) by Jet-Phillips Lighting, Inc. takes advantage of performance advances in high-wattage metal halide technology.

Discuss