Cold storage is one of the best places to put LED. Fluorescent struggles in the cold, metal halide takes forever to restrike, and every watt of heat a fixture gives off is heat the refrigeration has to remove. But not every LED fixture belongs in a freezer. Here is what to check.
Why LED works well in the cold
- Instant on in the cold. LEDs start at full output right away. Fluorescent lamps typically dim and flicker at low temperatures, and metal halide needs time to warm up.
- LEDs like low temperatures. Heat is what wears LEDs out, so a cold room is an easy environment for the diodes themselves.
- Less heat in the box. Lower wattage means less heat for the refrigeration system to pull back out.
- Works with sensors. LED can switch on and off or dim constantly without the lamp life problems of older sources.
What to check on the spec sheet
| Spec | What to look for |
|---|---|
| Operating temperature | The minimum ambient rating has to cover the room. Freezers often run well below 0°F, so confirm the fixture and driver are rated for it. |
| Location rating | Wet location rated for freezers and anywhere with condensation or washdown |
| IP rating | IP65 or higher is typical for vapor tight fixtures; IP66 or IP67 for heavy washdown |
| Lens | Shatter resistant polycarbonate, important in food areas where glass is a concern |
| Housing | Sealed, gasketed, with corrosion resistant hardware |
| Sensor rating | If a sensor is included, check it is rated for the same low temperature |
The driver is the weak point, not the LEDs. Electronics have a minimum operating temperature. A fixture that is fine in a 35°F cooler may not be rated for a minus 20°F freezer. Read the low end of the temperature range, not just the high end.
Condensation and doors
The hardest part of cold storage is not the cold. It is the moisture. Every time a door opens, warm humid air rushes in and condenses on cold surfaces, including fixtures. That is why a vapor tight fixture is the usual choice: sealed housing, gasketed lens and a wet location rating. For the details on ratings, see wet vs damp location and IP ratings.
- Avoid mounting fixtures right inside the door where warm air hits first, when you have the choice.
- Use proper wet location fittings and seal conduit entries so moisture cannot wick into the fixture.
- Areas that are pressure washed need a washdown rated fixture, not just damp rated.
Picking the fixture type
Walk in coolers and freezers usually have low ceilings, so a 4 ft or 8 ft vapor tight fixture is the most common choice. Large cold storage warehouses with tall racking often use high bays, as long as the high bay is rated for the room temperature and moisture.
For tall cold storage, compare linear high bays, which line up well with racked aisles, and UFO high bays for open areas. Confirm the low temperature rating on whichever you pick. To get the count right, use the lighting layout calculator and check the foot candle requirements by space type.
Sensors in cold storage
Cold storage aisles are often empty most of the day, which makes them a great fit for fixtures with occupancy sensors. Fewer hours on means less energy and less heat added to the room.
- Confirm the sensor temperature rating. Not every sensor is rated for a freezer.
- Dim instead of off in busy areas. Many sensors can drop to a low level so forklift drivers never enter a dark aisle.
- Pick the right sensor technology for the mounting height and aisle layout. See PIR, microwave and dual tech sensors.
- Add ons are available. Browse sensors and accessories for compatible options.
Cold storage runs long hours, so it is often a strong candidate for utility programs. Find out if there are rebates in your area, and check that the exact model is DLC listed if a rebate is on the table.
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