DC Distribution with LED Signage Case Study

Michael Petagna,
Director of Business Development
ROAL Electronics USA, Inc.

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Synopsis

Case study of a large channel letter sign with DC

distribution

Cooperating with a leading sign company, a large channel letter

sign installation that utilizes DC distribution
The installation includes 2 identical signs, each supplied 2000W of
remote power on the roof of a 17 story building
DC power is distributed to the roof through ROAL’s SignLINQ
technology providing Class 2 compliant power to the individual
channel letters
This paper is a case study of the design and installation of this sign

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Signage Details

2 Sign Structures are installed facing the East and West Sides
The total length of each sign is 82'-0", the total height is 23'-8"
Business School lettering is 7'-3" and the Rutgers is 9'-3"
The 'R' is 14'-0" high.
Final height of 307'-0" above street level.

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Signage Details

Installation of signage was

achieved with a 600 Ton
United Crane (DEMAG-AC-500)
using a 196'-0" jib
This crane is currently the
largest capacity hydraulic
crane in the U.S., and one of
only two on the East coast.
Total Sign Power = 1,100W
with 92Amps 12VDC
1,609 LED Modules used

Approximate Cost $450,000

Cost for DC Distribution = $4,200 inc. installation materials
Power Cost is less than 1% of total cost.

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Why Did Rutgers Choose LED Signage
with DC Distribution?
High Quality LEDs have 5 Year Warranty
Rudgers did not want to deal with transformer failures as
experienced with neon
The leading architect immediately saw the benefits of the DC
Distribution System, because all the power would be out of the
elements
Serviceability was a key factor – All the power was immediately
accessible

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Things to know about LEDs in Signs
LED signs still need to meet UL48 and UL1310 (In North America)
¾ 30VDC maximum for wet locations, 60VDC maximum for dry locations
¾ 100VA maximum
¾ 5A maximum
¾ Redundant over-current protection circuitry required
In North America, all wiring must meet NEC (National Electric
Code)
LED modules are not all the same
¾ Low quality/Cheap LEDs can be deceiving and they do not last
¾ Claims of 50,000 hours operation, but less than 3 year warranty
Power Supplies in Signs causes the most failures
¾ Typically the lowest cost component of the system but it contributes
to 85% of the failures
¾ Supplies are de-rated to 80% of full load to increase reliability

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Other issues
Sign Maintenance issues: LEDs will last longer than the power
supplies
¾ Conventional power supplies become a maintenance issue on
a regular basis after a few years of operation
¾ Signs are difficult to get to and difficult to service without
adding extra cost to the signs structure (i.e. access panels,
etc)

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Power Distribution Required
Using AC Distribution

R U T G E R S
Totals
LED Modules 208 124 81 113 96 130 91 843
Watts @ 1.44 149.76 89.28 58.32 81.36 69.12 93.6 65.52 606.96
Power Supplies 3 2 2 2 2 2 2 15
Amps 12.48 7.44 4.86 6.78 5.76 7.8 5.46 50.58

Supplies are de-rated to 80% as standard operating practice

B U S I N E S S
Totals
LED Modules 87 47 44 24 48 58 44 44 396
Watts @ 1.44 62.64 33.84 31.68 17.28 34.56 41.76 31.68 31.68 285.12
Total Supplies 2 1 1 1 1 1 1 1 9
Amps 5.22 2.82 2.64 1.44 2.88 3.48 2.64 2.64 23.76

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Power Distribution Required

S C H O O L
Totals
LED Modules 60 38 59 53 53 30 293
Watts @ 1.44 43.2 27.36 42.48 38.16 38.16 21.6 210.96
Total Supplies 1 1 1 1 1 1 6
Amps 3.6 2.28 3.54 3.18 3.18 1.8 17.58

Total Power Supplies Needed = 30

Alternate 240W MultiChannel Supplies = 9

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Decision point to use DC Distribution
AC solution required more complex wiring with many connections
Each power supply required separate housing on the sign structure
adding more costs
Too many possible failures at connection points
End customer wanted a low maintenance solution

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Signage Architect Selects
ROAL’s SignLINQ Product

8 Class 1 Branch Circuits

Greenbuilding Jan 2011 PETAGNA JAN 2011

 ROAL’s SignLINQ

Advanced Power
Solution
Increases reliability of
LED “System”
Reduces Power Supplies
in Sign
Easy Maintenance,
remote power supply is
easily accessible
Cost Effective for Large
installations

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Remote Power Source

Ventilation

Rain Proof Case

Security Lock

Hinged Access Door

16in (L) x 14in (W) x 6in (D)

35.56cm x 40.64cm x 15.24cm

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Remote Power Source (Inside)

Power Supply Module

8 Output Terminal Blocks (Fused)

Class 1 DC Circuits

Power Supply Tray for easy assembly

Optional Service Disconnect

Greenbuilding Jan 2011 PETAGNA JAN 2011

 MultiLINQ Basic Function
Patent No. US 7,804,189

The MultiLINQ is a Power Splitter

A single DC input is “split” into 4 individually controlled constant
voltage outputs
Each output is microprocessor controlled to maintain NEC Class 2
ratings
¾ When Vin <= 20VDC, I out limited to 5A maximum
¾ When Vin >20VDC, output power limited to 100VA, I out is linearly
programmed according to input voltage
Output voltage follows input voltage within 200mV
Reverse input and output voltage protected
Wide input operation (6VDC to 28VDC)
Power good LED, Fault alarm LED and external signal

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Actual Power Distribution

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Actual Power Distribution

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Actual Power Distribution

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 Actual Power Distribution

General Knowledge of Distribution losses is required

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Cost Comparison of AC vs DC

AC Distribution
Item Unit Cost Quantity Extended Cost

60W LED Power Supplies $45 30 $1,350

Alternate 240W 4 Output $208 9 $1,872

DC Distribution
Item Unit Cost Quantity Extended Cost

2 RPS 1000W Supplies $600 2 $1,200

MultiLINQ Power Splitters $99 8 $792

Total $1,992
•The extra $120 for DC Distribution for a $450K project is negligible
•One Power Supply failure will cost $110 just for the service call

Greenbuilding Jan 2011 PETAGNA JAN 2011

 DC Distribution Proved to be
a “cleaner” implementation

Power Splitters are hidden

from view with less connection
points

The Signage Structure does not

contain any AC Voltage

Aesthetics of the signage are

improved during daylight
hours

Overall Reliability improved

Greenbuilding Jan 2011 PETAGNA JAN 2011

 Benefits vs Drawbacks
DC Solution provides a single point of failure essentially
¾ Power Splitters do not convert power and have 2.5M Hour MTBF
¾ 2 Centralized Power Converters vs 30 individual power supplies
Total System Efficiency with Distributional Losses is 81%
¾ AC Supplies are estimated to be approx 81% typical
DC Solutions require some knowledge of voltage drops and
distribution losses
DC Solutions are still not common, making them less accepted in
traditional markets….. UNLESS …… You Create a Compelling
Reason for Designers to spec them, and installers to Install them
!!!

Greenbuilding Jan 2011 PETAGNA JAN 2011

Greenbuilding Jan 2011 PETAGNA JAN 2011