2000W Metal Halide, Halogen LED Replacement – How to Retrofit?

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2000 watt metal halide and halogen replacement with LED

Why do we need to replace 2000W metal halide and halogen with LED?

replacing 2000W metal halide light bulbsThe structure of a 2000W metal halide or halogen bulb entails some problems. Mainly, some risks are related to the quality of the heating that they can provide. Both metal halide and halogen lights can burn things too close to them. This applies to people under the light they emit and accessories or materials above.

When you replace an HID or incandescent fixture with a LED retrofit, the heat problem shrinks considerably. In fact, the 2000 watt LED equivalent dissipates the heat efficiently via an inbuilt heat sink.

Power consumption is also a big factor. An equivalent LED light with the same lumen output of an MH or Halogen light consumes way less than their counterparts.

Next, we could discuss the inferior metal halide and halogen lamps’ life span. LED lasts hundreds of thousands of hours, while an MH floodlight can barely make it to 50,000 hours. Most likely, a 2000W halogen light would hardly reach the 2000-hour mark.

In the end, LED lights are more efficient and more cost-effective than other fixture types. Since the end result is the same, you should replace them with a more convenient LED retrofit.

How to replace 2000W metal halide?

1. Lumen of 2000W metal halide bulb

2000W metal halide lumensClearly, the first task involves finding the equivalent LED retrofit. To do that, we must find a LED product with the same lumen output of the light you will change.

Of course, you need to know how many lumens a 2000W metal halide lamp produces first. You can find the lumen value of each light source on the packaging. Or by looking for each model on the manufacturers’ websites.

Roughly, a 2000 watt MH emits between 140,000 and 210,000 lumens.

2. Power equivalent

The LED power equivalent of a 2000W metal halide consumes between 800 and 1200 watts. Usually, the higher the wattage, the higher the lumens. So, if you need to buy a LED retrofit for replacing a professional sports light, get the higher watt consuming LED replacement.

When deciding on the replacement’s wattage, remember that metal halide bulbs lose their light output quickly due to light loss factors such as:

  • overheating
  • dirt
  • age
  • operating conditions
  • manufacturing defects

3. Bulb base

Choosing a LED retrofit can be tricky. Even though you have selected the right equivalent light that has the most cost-effective wattage. In fact, you must make sure to choose the correct bulb base as well.

LED retrofit screws into the MH or halogen lamp holder. But, the screw base just holds the LED replacement in place. It does not absorb energy. Nonetheless, you need to select a replacement with the same base.

Most MH lights have a large E40 (Goliath) or E39 (Mogul) base.

4. Input voltage

Most LED retrofits come with a driver. That is, a device that lets you use low voltage. Mostly, LEDs need 12-24 volts. But the electricity running through the wire can be anywhere between 120-290 volts. Besides, the driver converts alternating current to direct current for optimal power supply.

You need to connect the LED retrofit to the driver to protect the diodes from currency fluctuations. In short, input overvoltage and undervoltage can cause the LED light to not work as intended. What is worse, these changes in voltage shorten the LED life span.

You can find products with internal and external drivers. Mainly, picking the most appropriate one depends on the lighting system. If you already installed a driver, you would not need another. When shopping for replacements, read the product descriptions.

5. Ballast removal

removing-the-ballast-when-replacing-metal-halide-lights-with-LEDOnce you are ready to install the HID replacement, you need to turn the power off. Next, remove the metal halide ballast and starter. The main goal of the ballast is to provide the starting voltage for the MH to light up. But no LED light requires such a voltage variation.

First, remove the MH bulb and cut the wires going to the ballast. Then, proceed to take away the device and the remaining cables.

Now, you should have plenty of space to place the driver and connect the hot and the neutral to it. Finally, you can insert the LED retrofit, turn the power back on, and test the new light.

How to replace 2000W halogen flood lights?

1. Lumen of 2000W halogen flood light

The typical 2000W halogen lamp’s initial lumens are around 59,000. Halogen bulbs were an evolution of incandescent bulbs. In fact, what differentiates them from the latter is the presence in the bulb of a gas. Indeed, the only difference is the combination of krypton (or xenon) and the tungsten filament. They guarantee longer life and greater light intensity for the same consumption than an incandescent light.

Most halogen lamps have a lumen per watt ratio of 22-30 lm/W. So, you will not have any problem finding a LED replacement.

2. Wattage equivalent

The LED power equivalent of a 2000W halogen bulb consumes way less than half. Broadly speaking, LED has 10 times higher luminous efficacy than halogen flood lights. So, you can simply divide the halogen wattage by 10:

2000W/10 = 200W

Roughly, you need a 200 watt LED light to replace a 2000W halogen bulb. For converting professional halogen sports light fixtures, you might have to choose a LED retrofit up to 600W. In fact, the shape and size of the halogen bulb might require you to select specific LED models.

3. Bulb base

Mostly, halogen lamps connect to an R7s socket or G38 ceramic lamp holder. So, you can either find an adapter or install a new socket.

A LED conversion of halogen flood lights involves several steps. You would need to remove the lens cover first. Unscrew any bolt that prevents you from pulling off the lens cover to make space. As well as any screw that holds the reflector for the bulb holder removal. Now, you can use some thermal grease to attach the LED light to the casing. As you might imagine, the case dimensions will narrow down the selection of suitable LED lights to 200W chip LED COB (Chip on board).

The simplest solution is to use R7S LED bulbs.

4. Soldering considerations

If you use an equivalent LED chip, you need to solder the wires to the LED. Make sure to check that you solder it right. As they work on 110-120 or 220-240 volts, I already presume that you selected the right one for your project.

It does not matter which wire you connect on which side, but keep the uncovered leads extremely short. More importantly, check that everything is done correctly at this point. The LED chip must light up when you turn it on.

Only then apply the thermal grease. For smaller projects, you can use thermal grease for connecting PC heat sinks to the central processing unit (CPU).

Applications of LED retrofit of 2000W metal halide and halogen

1. Sports field

football field 2000W MH replacement and retrofit

For over a decade now, LED lights have replaced HID and incandescent lights in sports facilities. You should convert the metal halide or halogen lights to equivalent LED retrofits in any:

  • football field
  • tennis court
  • cricket stadium
  • golf course
  • baseball field
  • indoor softball turf
  • rugby pitch
  • ice hockey rink
  • hockey field
  • velodrome

By replacing each 2000W HID/halogen light, owners have saved a lot of money. Moreover, LED lights do not need to cool down when you turn them off. So, they are more practical and better suited for sports arenas and tournaments.

2. Industrial lighting

replacement of 2000W halogen flood lightsWithout any doubt, LEDs have taken over the industrial lighting sector as the most reliable lighting solution. You can find LED lights in any industrial area such as:

  • warehouses
  • factories
  • seaports
  • airport aprons
  • canteens
  • steel mills
  • cold rooms
  • weapons development facilities

Mostly for better safety reasons.

No 2000 watt equivalent LED retrofit will ever heat up as much as the original MH or halogen lamp. Therefore, you can use LED lights in many enclosures that were off-limits before. Maintenance-wise, LED lights are easy to clean and rarely replaced because of their long life span. So, they are just convenient for any application in industrial settings.

Safety precautions when replacing 2000W MH and halogen bulb

1. Avoid touching the bulb with your hands

Grease from your hands may crack the bulb in the future. So, always wear protective gloves when handling the MH or halogen bulb. Then, clean the glass bulb with a clean cotton cloth and warm water.

Likewise, make sure that the bulb has cooled down before touching it. Even when wearing protective gloves, the temperature can be a problem. In fact, metal halide lamps contain mercury vapors. So, if the MH bulb breaks in your hand, you could end up inhaling dangerous heavy metals.

2. Using the proper input voltage

At the industrial level, complex HV/MV and MV/LV systems are in place. Basically, these systems are useful because they allow power distribution over large distances. They optimize the sizing of electrical conductors. But at the same time, they cause a voltage drop due to the specific conductor resistance. This is why so many nominal frequencies and voltages exist in different countries of the world.

You must use an equivalent LED retrofit that works with the correct input voltage range. So, ask for the power supply specifications in case you are not sure about which voltage runs through your home or factory.

3. Ultraviolet radiation and eye care

Halogen and metal halide lamps can cause damage to the skin and eyes. In fact, a 2000 watt MH or halogen bulb emits UV rays. So, do not turn the old bulb on after you remove the protective glass or lens cover.

Sometimes, when converting an old HID flood light to a LED light, some people forget that LEDs do not have a warm-up period to reach their full lumen output. When installing the 2000W equivalent LED retrofit, you certainly need to test it. But beware of its brightness as it can cause glare and temporarily blind you.

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