Upgrading Emergency Lighting: LED, Self-Test, Emergency Drivers

When does upgrading make sense?

Upgrading emergency lighting means the planned replacement or retrofit of an existing installation to bring it up to current technical, regulatory and documentation standards. Age alone does not make an upgrade mandatory – as long as the installation meets the requirements and is demonstrably tested. In practice, however, older installations tend to combine several problems.

Typical warning signs:

• Fluorescent lamps in emergency luminaires: since 2023, most fluorescent lamps may no longer be placed on the EU market under the RoHS Directive. Replacements are becoming scarce and expensive.
• NiCd or old NiMH batteries: they age noticeably, lose capacity and often fail to reach the rated duration in the annual test. NiCd also contains the heavy metal cadmium.
• Frequent faults: flashing red status LEDs, recurring battery faults, luminaires failing the functional test.
• No spare parts: manufacturer no longer trading, matching batteries or control gear unavailable.
• Missing or incomplete documentation: no logbook, no photometric calculation, no system drawings.
• Changed use: refurbishment, new room layout, new escape routes or a change of use, such as from warehouse to retail.
• High testing workload: manual monthly tests in large buildings or on hard-to-reach luminaires.

What the individual fault indications mean is explained in Emergency light flashing red.

What are the benefits of LED in emergency lighting?

A large part of the benefit lies not in energy savings but in testing: luminaires with automatic self-testing carry out functional and duration tests on their own and log the results. More on this in Self-testing emergency lights. For battery technologies, see Emergency light batteries.

What retrofit options are there?

Replacing the emergency luminaires

The most common route is replacing old emergency luminaires and exit signs with LED luminaires that have an integrated battery. In a self-contained system, each luminaire has its own battery and is connected to the normal supply. There is no battery room and no fire-resistant cabling, which makes the switch comparatively straightforward in existing buildings.

Emergency drivers for existing LED luminaires

If the general lighting has already been converted to LED, some of these luminaires can become emergency luminaires by adding an emergency driver. An emergency driver is a module with its own battery that keeps the LED luminaire running at reduced output during a mains failure. This is particularly useful in industrial halls, where installing extra emergency luminaires at great height would be costly. NOTLUX offers emergency drivers for existing LED fittings and an IP65 version for LED high-bay luminaires up to 300 W, each with 90 minutes of emergency operation.

Important: whoever modifies a luminaire generally takes on responsibility for its conformity. The converted luminaire must meet the requirements for emergency luminaires in EN 60598-2-22, and the driver's duration must match the required rated duration. Where three hours are required, a 90-minute driver is not sufficient.

Central battery or self-contained?

With existing central battery systems, the question is whether to modernise the central unit or switch to self-contained luminaires. That depends on building size, the condition of the wiring and the requirements of the fire safety strategy. See Self-contained vs central battery for guidance.

How does an upgrade project work?

• On-site survey: record all luminaires, signs, operating modes, batteries and circuits; review existing documentation and current escape routes.
• Concept: compare against the applicable requirements (EN 1838, EN 50172, national rules such as DIN VDE V 0108-100-1 in Germany, the building permit and the fire safety strategy), carry out a photometric calculation, select luminaires and optics, define the rated duration.
• Installation: replacement or retrofit, coordinated with operating hours, section by section rather than all at once.
• Handover and documentation: initial verification, functional and duration test, handover of system drawings, calculation and logbook.
• Maintenance: ongoing tests at fixed intervals, battery replacement as specified by the manufacturer, adjustments after alterations.

NOTLUX records testing and maintenance digitally via an app; the built-in LiFePO4 batteries are replaceable and last at least five years. The maintenance contract includes the annual inspection, replacement of all batteries in year 5 to 6 and repairs.

How do you avoid downtime during the upgrade?

The building must remain safe throughout the works. Proven approaches:

• Work section by section: convert one area at a time, so that a working escape lighting system is always in place.
• Use off-peak hours: nights, weekends or production breaks, especially in manufacturing, retail and hospitality.
• Install new luminaires first: with self-contained luminaires, new fittings can be installed and commissioned before the old ones are removed.
• Allow for charging time: new batteries need time to charge fully before the first duration test is meaningful.
• Agree interim measures: if an area is temporarily without escape lighting, organisational measures are needed, agreed with the person responsible for fire safety.

Checklist: is your emergency lighting a candidate for an upgrade?

• Are fluorescent lamps or NiCd batteries still installed?
• Do luminaires fail the annual test because their duration is too short?
• Are spare parts available for every luminaire type?
• Is there a complete logbook for recent years?
• Is there a photometric calculation that matches the current layout?
• Do the exit signs comply with ISO 7010?
• Is the monthly testing workload manageable with the staff available?

If you answer yes to either of the first two questions, or no to any of the others, an on-site survey is worthwhile.