5YR. Advanced LED lighting. High performance industrial lighting. 50% energy against traditional fittings Up to 75% energy saving with sensing

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1 High performance industrial lighting 50% energy against traditional fittings Up to 75% energy saving with sensing Zero maintenance, no need to relamp IK10 rated durable construction Advanced LED lighting 5YR 5 year commercial extended warranty. Register online at jcc.co.uk

2 5YR a company We believe that a manufacturers warranty is your assurance of quality. This is why all Toughbay products feature our industry leading five year commercial extended warranty. All of our products are independently tested to ensure that they perform to the highest standards. To register your warranty, simply go to: jcc.co.uk/warranty Service & support If you have any questions about the Toughbay range please contact a member of our support team. Customer services Technical support sales@jcc.co.uk Zero maintenance, no need to relamp Toughbay provides a true fit-and-forget lighting solution that eliminates the high costs associated with relamping. Unlike traditional fluorescent and HID fittings, Toughbay s lifespan is not affected by frequent on/ off switching. This makes Toughbay ideal for use with control systems to further improve energy savings. Instant start-up, no warm up time HID (SON & metal halide) lamps take up to 10 minutes to start and reach then full brightness. Toughbay provides full illumination as soon as it s switched on. High specification for a wide range of applications Toughbay products deliver maximum durability. All products provide IP65 protection against dust and moisture as well as holding the maximum impact rating of IK10. This ensures that Toughbay is suitable for the harshest of environments. Designed for use with controls All products within the Toughbay range are 1-10V dimmable as standard. Unlike traditional industrial light fixtures, Toughbay is ideal for use with control systems to further maximise energy savings. Toughbay products have been specifically designed for use with our Leviton Multi-function sensor. See page 16.

3 Direct HID metal halide replacement Ideal for open area illumination Ultra efficient with over 100 LpcW Multiple mounting options available Wide range of accessories available Direct HID low bay and T5 fluorescent replacement Ideal for high racking applications Highly efficient, up to 100 LpcW Adjustable mounting points for easy installation Opal diffuser for reduced glare 100W 10,600 lumens Replaces 150W HID 75W 7,500 lumens Replaces 150W HID 180W 19,700 lumens Replaces 250W HID 150W 14,000 lumens Replaces 4x43W T5 fluorescent 230W 23,700 lumens Replaces 400W HID 210W 19,000 lumens Replaces 4x80W T5 fluorescent ENERGY SAVING Up to 48% BEAM ANGLE 105 /60 with reflector ENERGY SAVING Over 50% BEAM ANGLE 110 L70 50,000 hours IP RATING IP65/IP67 connector L70 50,000 hours IP RATING IP65/IP67 connector Tel:

4 Industrial lighting Application guide Production areas: 500 lux Toughbay Linear 75W 2ft Linear surface mounted SEE PAGE 12 Open areas: 300 lux Toughbay Circular 230W Suspended with reflector SEE PAGE 9 Retail/showrooms: lux Toughbay Circular 100W Surface mounted without reflector SEE PAGE 8 Aisle/racking: lux Toughbay Linear 210W 5ft Linear suspended SEE PAGE 14 2

5 Ideal for open areas to provide wide even light distribution Direct HID metal halide replacement Wide 105 beam angle (without reflector) Focused 60 beam angle (with reflector) IP65 as standard 1-10V dimmable as standard Ultra efficient, over 100 LpcW 105 beam angle (Without reflector) 100W 180W 230W 4m/Ø10m 260 lux 4m/Ø10m 220 lux 6m/Ø15m 260 lux 6m/Ø15m 116 lux 6m/Ø15m 124 lux 8m/Ø20m 150 lux 60 beam angle (With reflector) 100W 180W 230W 4m/Ø4.6m 469 lux 4m/Ø7m 504 lux 8m/Ø9.2m 334 lux 6m/Ø7m 208 lux 6m/Ø9.2m 284 lux 10m/Ø11.5m 214 lux 12m/Ø13.9m 150 lux Indicates diametre of the beam at distance Indicates distance measured from fitting Ideal for aisle & racking areas Direct HID and fluorescent replacement IP65 as standard 1-10V dimmable as standard Suitable for high racking applications Linear form provides required light distribution for aisles Adjustable mounting points for easy installation 110 beam angle 75W 150W 210W 2m/Ø5.6m 280 lux 3m/Ø8.6m 135 lux 4m/Ø11.5m 203 lux 6m/Ø15m 223 lux 4m/Ø11.5m 100 lux 5m/Ø14.2m 130 lux 8m/Ø20m 150 lux CIBSE Guidelines for industrial applications CIBSE (Chartered Institution of Building Services Engineers) guidelines for industrial applications. Aisle/racking Mounted at 10m lux Open Areas Mounted at 8m 300 lux Measured at 0.75m from floor level. Retail/Showrooms Mounted at 8m lux Production Areas Mounted at 6m 500 lux 3

6 Eliminates the high maintenance costs of relamping Industrial light fixtures are often positioned at inaccessible heights that require the use of a cherry picker and operator to resolve lamp failures. The replacement of traditional HID lamps can pose a significant cost to businesses as well as causing considerable disruption. The wide light distribution achieved by industrial lighting fixtures means that any lamp failures result in a larger area of light loss. This heightens the requirement for lamp replacements within industrial applications, further increasing maintenance costs. For this reason businesses often choose to undertake regular lamp replacement programmes for HID fittings. This not only incurs significant costs, but also has a negative effect on productivity due to extensive downtime during the replacement period. Toughbay s ultra durable design, IP65 rating and intelligent thermal management ensures a reliable, long lifespan that eliminates the high costs associated with HID and fluorescent lighting. Toughbay lasts up to 5 times longer than traditional lighting T8 fluorescent T5 fluorescent Metal halide SON Toughbay 10,000 hrs 14,000 hrs 18,000 hrs 20,000 hrs 50,000 hrs 0 10,000 20,000 30,000 40,000 50,000 Hours (to L70) In addition to lamp life, lumen maintenance is also a key factor. Toughbay s life expectancy is rated at 50,000 hours to L70, this means that greater than 70% of the original lumen output is delivered by the fitting at 50,000 hours. In contrast, traditional lighting fixtures reduce to 70% within a significantly shorter life span. 4

7 Designed for maximum durability IP65 protection against dust & moisture All Toughbay products are IP65 rated to provide protection against dust, moisture and environmental contaminants. This ensures that Toughbay is an ideal choice for harsh environments. Maximum impact resistance Toughbay products provide the maximum impact resistance rating of IK10. Traditional lamp based lighting fixtures have a low impact rating and pose a high risk of shattering. This not only increases the probability of lamp failures but also results in many fixtures requiring protection from falling glass into the working environment. Suitable for extreme operating temperatures Traditional lamps and ballasts have a limited range of start up temperatures. This can often conflict with the ambient temperatures within the application, resulting in poor performance and ineffective lighting. Toughbay has been designed to operate perfectly within a temperature range of -30º to +60º. This makes Toughbay ideal for use in applications from cold storage facilities to industrial foundries. Toughbay does not emit UV light, eliminating the issue of stock discolouration Ideal for retail applications Traditional HID and fluorescent lamps emit UV light that bleaches products. This has an adverse effect on stock and goods within the lit space. In retail applications this can result in additional stock rotation to ensure that there is no noticeable stock discolouration. Consistent colour temperature HID metal halide lamps suffer from colour shift, where the colour temperature alters throughout the life of the lamp. Not only does this look unsightly, but it creates inconsistency that can misrepresent colour. High CRI Toughbay has a high CRI of 80, providing clarity in production areas and making products look their best in retail environments. Toughbay maintains a consistent colour temperature and high CRI to ensure a true representation of colour throughout its life. Tel: sales@jcc.co.uk 5

8 Toughbay Circular Innovative, stylish design MULTI-ARRAY LED CHIPS The LED array assists in the dissipation of heat over the full surface area of the fitting, helping the product to stay cooler & improve reliability. IMPACT RESISTANT POLYCARBONATE DIFFUSER Toughbay Circular s high quality polycarbonate shatter proof diffuser provides extra safety and assurance in the work place. CAST ALUMINIUM BEZEL Made to the highest specification, the bezel includes a silicone gasket to maintain an IP65 rating. Ideal for open areas to provide wide and even light distribution Direct HID metal halide replacement 105 beam angle without reflector 60 reflector beam angle option Leviton multi-function sensor available for further energy savings Versatile mounting options Ultra efficient, over 100 LpcW 50,000 hours life to L70 6 web: jcc.co.uk/toughbay

9 HIGHLY DURABLE DRIVER Toughbay s highly efficient driver can operate in a range of temperatures from refrigeration to industrial foundries. MOUNTING LOOP Comes fixed as standard for quick and easy installation. See page 15 for more mounting options. BACK PLATE Covers the driver and further protects from dust, moisture and environmental contaminants. IP67 CONNECTOR Toughbay s durable connector makes it suitable for the harshest of applications. Outstanding cost savings Annual Lifetime Lifetime Extended cost saving cost saving CO 2 reduction warranty 17, , T/CO 2 e 5 years* Energy and maintenance savings based on 100 x Toughbay Circular 230W vs 100 x 400W metal halide. Annual usage of 12 hours per day, 365 days per year, over a 5 year period. Energy tariff 0.15 per kwh. 50% lamp failure rate. Lamp replacement costs include cherry picker hire of 300 per day and labour costs of 640 (2 contractors for 8 hours at 40p/h). Average of 16 HID lights changed over an 8 hour period. Overall lamp change cost of per fitting. Tel: sales@jcc.co.uk 7

10 100W Direct replacement for 150W metal halide 40% energy saving against HID 105 beam angle without reflector 60 reflector beam angle option, available page 15 Surface mount bracket available page 15 50,000 hours life to L70 Leviton microwave sensor available for further energy savings Suitable for retail and mezzanine applications Supplied with mounting ring as standard Available in black or white finish JC71810WH Toughbay 100W Code Colour temp. Lumens Wattage LpcW IP rating Beam angle JC71810WH 5700K 10, W 106 IP JC71810BLK 5700K 10, W 106 IP mm 130mm 8 web: jcc.co.uk/toughbay

11 Direct replacement for 250W & 400W metal halide 180W & 230W Up to 48% energy saving against HID 105 beam angle without reflector 60 reflector beam angle option, available page 15 Surface mount bracket available page 15 50,000 hours life to L70 Leviton microwave sensor available for further energy savings Suitable for medium (250W) and high (400W) mounting applications Supplied with mounting ring as standard Black finish JC71811BLK Toughbay 180W & 230W Code Colour temp. Lumens Wattage LpcW IP rating Beam angle JC71811BLK 5700K 19, W 109 IP JC71812BLK 5700K 23, W 103 IP mm 150mm Tel:

12 Toughbay Linear Ultra stylish, high output design INTELLIGENT THERMAL MANAGEMENT Toughbay s fully integrated heat sink is designed to specifically improve airflow and maximise heat dissipation to help reduce the operating temperature of the fitting and improve reliability. IMPACT RESISTANT POLYCARBONATE LED DIFFUSER Toughbay Linear s high quality polycarbonate diffuser is shatter proof providing extra safety in the work place. Ideal for high racking applications Direct HID and fluorescent replacement Consistent Toughbay colour temperature & construction 50,000 hours life to L70 Opal diffuser for reduced glare Ideal for high racking applications Leviton multi-functional sensor available for further energy savings Adjustable mounting points for easy installation 10 web: jcc.co.uk/toughbay

13 MOUNTING LOOP Comes fixed as standard for quick and easy installation. MOUNTING BRACKET Toughbay s unique mounting bracket is fully adjustable making it versatile and the perfect retrofit solution. REFLECTOR Toughbay Linear s high quality reflector ensures that light is evenly distributed, providing a crisp clear light. This makes it ideal for task lighting and areas that require fine detail. TRIPLE-ARRAY LED CHIPS Toughbay Linear uses the latest high output LED chips, providing up to 100 LpcW. The triple array is designed to provide even light distribution. Outstanding cost savings Annual Lifetime Lifetime Extended cost saving cost saving CO 2 reduction warranty 21, , T/CO 2 e 5 years* Energy and maintenance savings based on 100 x Toughbay Linear 210W vs 100 x 4x80W T5 fluorescent fittings. Annual usage of 12 hours per day, 365 days per year, over a 5 year period. Energy tariff 0.15 per kwh. 50% lamp failure rate. Lamp replacement costs include cherry picker hire of 300 per day and labour costs of 640 (2 contractors for 8 hours at 40p/h). Average of 16 HID lights changed over an 8 hour period. Overall lamp change cost of per fitting. Tel: sales@jcc.co.uk 11

14 75W Direct replacement for 150W HID low bay Over 50% energy saving against HID Consistent Toughbay construction and colour temperature 110 beam angle 50,000 hours life to L70 Suitable for production and manufacturing low bay applications Suitable for cold storage areas and freezers Supplied with two mounting rings as standard Adjustable mounting points for easy installation Leviton microwave sensor available for further energy savings JC71901WH Toughbay Linear 2ft 500mm max 300mm min Adjustable mounting points for easy retrofit installation 73mm 103mm 240mm 620mm Code Colour temp. Lumens Wattage LpcW IP rating Beam angle JC71901WH 5700K 7,500 75W 100 IP JC71901BLK 5700K 7,500 75W 100 IP web: jcc.co.uk/toughbay

15 150W Direct replacement for 4x54W T5 fluorescent 40% energy saving against fluorescent Consistent Toughbay construction and colour temperature 110 beam angle 50,000 hours life to L70 Suitable for medium height racking applications Suitable for cold storage areas and freezers Supplied with two mounting rings as standard Adjustable mounting points for easy installation Leviton microwave sensor available for further energy savings JC71902BLK Toughbay Linear 4ft 1000mm max 300mm min Adjustable mounting points for easy retrofit installation 73mm 103mm 240mm 1216mm Code Colour temp. Lumens Wattage LpcW IP rating Beam angle JC71902WH 5700K 14, W 93 IP JC71902BLK 5700K 14, W 93 IP Tel:

16 210W Direct replacement for 4x80W T5 fluorescent 45% energy saving against fluorescent Consistent Toughbay construction and colour temperature 110 beam angle 50,000 hours life to L70 Suitable for a wide range of production and manufacturing applications Suitable for cold storage areas and freezers Supplied with two mounting rings as standard Adjustable mounting points for easy installation Leviton microwave sensor available for further energy savings JC71903BLK Toughbay Linear 5ft 1200mm max 300mm min Adjustable mounting points for easy retrofit installation 73mm 103mm 240mm 1520mm Code Colour temp. Lumens Wattage LpcW IP rating Beam angle JC71903WH 5700K 19, W 90 IP JC71903BLK 5700K 19, W 90 IP web: jcc.co.uk/toughbay

17 Toughbay Circular Reflectors & accessories Reflectors JC71852BLK 60 beam angle reflectors Designed to compliment the Toughbay range Ideal for reducing glare and increasing lux levels directly beneath the fitting Clear polycarbonate reflector available (100W only) suitable for retail applications Quick 4-screw installation Leviton microwave sensor reflector clip attachment available (see page 16) JC71854BLK (100W) JC71854PR (100W) JC71852BLK (180W/230W) Ø390mm 210mm Ø395mm 200mm Ø520mm 300mm Reflector clip The Leviton multi-function sensor (LEV71904BLK) comes with additional connector for installation on all Toughbay reflectors. Surface mounting bracket Quick 4-screw surface mount bracket attachment JC71850BLK Shown with JC71811BLK White finish available for smaller 100W fitting only L R Tiltable bracket (L) 180 tilt featured as standard for wall and post mounting applications (R) Horizontal tilt suitable for external floodlighting JC71855/56 378mm 90mm 210mm JC mm 90mm 239mm Waterproof IP67 connector Superior levels of dust and water ingress protection Ideal for harsh industrial applications JC mm 75.3mm JC71851BLK Tel: sales@jcc.co.uk 15

18 Reduce your energy use by a further 50% Unlike HID, LED is perfectly suited for use with controls HID metal halide lamps typically require a 15 minute cool down period when switched off before re-strike, making them unsuitable for use with energy saving occupancy sensors. Whilst fluorescent lamps can be switched on and off, the frequent on/off switching will reduce lamp life by up to 75%, leading to significant maintenance costs. LED is not only twice as efficient as traditional light sources, but when used in conjunction with microwave sensing can reduce energy consumption by a further 50%. Furthermore, Toughbay Sensor is 1-10V dimmable as standard so whether you are looking to implement dimming control now or in the future, significant running cost savings can be achieved at any time. LEV71904BLK Multi-function sensor Microwave on/off sensing Step dimming Connects with all Toughbay products Wide detection range for precision control On/off sensing Step dimming Without occupancy the lights remain off Adjustable hold time from 5 secs - 30 minutes Without occupancy the lights dim to 10% - 50% of full illumination Adjustable standby dimming time from 5 secs - 60 minutes On/off sensing can be the most effective way to maximise energy savings for areas that are infrequently used and require lights off when there is no occupancy. This makes on/off sensing the most suitable control solution to use in low footfall areas such as storage areas and loading bays. For higher occupancy areas, such as high rack applications, there may be little or no external lighting contributing to the lighting levels. Having the lights off may compromise the safety to employees if there are unexpected obstacles along the dark aisles. Retaining a low level of lighting when there is no occupancy increases visibility into areas that are not in use and increases awareness of obstacles or potential hazards. 16 web: jcc.co.uk/toughbay

19 Energy savings achieved without using controls Energy savings achieved using controls Percentage of energy used in comparison to old lamp technology 100% 75% 50% 25% 0% 50% INITIAL SAVING 50% TOTAL SAVING ADDITIONAL 30% ADDITIONAL 50% 65% TOTAL SAVING 75% TOTAL SAVING 400W HID Metal Halide Toughbay Standard fitting Toughbay Microwave step dimming Toughbay Microwave on/off When combining Toughbay 230W with occupancy on/off sensing, an astonishing 75% energy savings can be achieved against 400W HID without compromising safety in the workplace. Wide detection range for precision control 16m wide detection range The ultra-wide 16m detection range allows installers to control specific high footfall and low footfall areas using both on/off and step dimming sensing. The detection range can be adjusted up to 50% by using the dip switches. Up to 15m mounting height The Leviton multi-function sensor is suitable for mounting heights up to 15m making it the ideal solution for retail and industrial applications. Designed for simple, versatile installation Reflector clip The Leviton multi-function sensor comes with additional connector for installation on all Toughbay reflectors. Direct connector The Leviton multi-function sensor can be connected directly to both Toughbay Circular and Linear fittings. Remote sensing To provide complete control the Leviton multi-function sensor can be installed remotely at specified locations. Tel:

20 Code Description Colour temp. LED Lumens LpcW IP Beam JC71810WH Toughbay Circular 100W 5700K 100W 10, IP JC71810BLK Toughbay Circular 100W 5700K 100W 10, IP JC71811BLK Toughbay Circular 180W 5700K 180W 19, IP JC71812BLK Toughbay Circular 230W 5700K 230W 23, IP LED Construction Class 5700K Body Cast aluminum Class 1 CRI:Ra (80) Diffuser Clear polycarbonate IP65 Max.working temp V Min.working temp. -30 Code Description Colour temp. LED Lumens LpcW IP Beam JC71901WH Toughbay Linear 2ft 5700K 75W 7, IP JC71901BLK Toughbay Linear 2ft 5700K 75W 7, IP JC71902WH Toughbay Linear 4ft 5700K 150W 14, IP JC71902BLK Toughbay Linear 4ft 5700K 150W 14, IP JC71903WH Toughbay Linear 5ft 5700K 210W 19, IP JC71903BLK Toughbay Linear 5ft 5700K 210W 19, IP LED Construction Class 5700K Frame Extruded aluminum Class 1 CRI:Ra (80) End caps - Cast aluminium IP65 Diffuser Polycarbonate 240V Max.working temp. 60 Min.working temp. -30 Calculate your cost savings Download JCC s free cost saving app to see how much money you could save by using any Toughbay fitting. Simply enter the number of fittings that you require and see your precise energy reduction and cost savings. Reflectors & accessories Code Description Finish JC71854PR Toughbay Circular 60 reflector (for 100W) Prismatic JC71854BLK Toughbay Circular 60 reflector (for 100W) Black JC71852BLK Toughbay Circular 60 reflector (for 180W & 230W) Black JC71856 Toughbay Circular surface mounting bracket (for 100W) White JC71855 Toughbay Circular surface mounting bracket (for 100W) Black JC71850 Toughbay Circular surface mounting bracket (for 180W & 230W) Black JC71851 Toughbay Circular waterproof IP67 connector Black LEV71904BLK Leviton multi-function sensor mounting clip Black LEV71904WH Leviton multi-function sensor mounting clip White JCC s cost saving app is available for free on both ios & Android devices. a company sales@jcc.co.uk jcc.co.uk JCC Lighting Products Ltd Innovation Centre, Beeding Close, Southern Cross Trading Estate, Bognor Regis, West Sussex PO22 9TS JCC Lighting Products Ltd 2015 LIT0139 Version 1