Solar-powered lighting solutions for office and industrial spaces are in increasingly high demand. The opportunity to save money and lighten the company’s carbon footprint is just one reason why business leaders are making the switch to solar. But before you invest in a system that will serve you for many years to come, you want to know exactly how it works. Follow this guide to learn more about practical details, logistics, and safety considerations for the FUSION LED lighting system. 

FUSION is by far the best solar-powered LED lighting on the market right now. It has both commercial and industrial applications, from office troffers to production area high bays. Its efficiency outranks any other LED office lighting. FUSION LED systems can provide all or a majority of light from solar panels when electricity costs are at their highest.

What makes this product the best solar-powered light? Its innovative technology, which garnered the Plant Engineering 2018 Product of the Year Award. The FUSION Energybank LED system features:

  • Photovoltaic solar
  • Solid-state lighting
  • IoT (Internet of Things)
  • Environmental stewardship

In this way, the FUSION systems deliver energy and grid parity costs at the point of use. Traditional grid systems for solar power can be expensive to install and maintain and actually lose lots of power during transfer. FUSION eliminates all of the expensive, high-maintenance, and inefficient equipment and processes required for a traditional grid-connected system and makes the most effective use of the solar energy harnessed.

So, that’s a snapshot of what the FUSION LED Lighting System is and what makes it special. Now let’s get into the practical details and logistics for all you contractors who’d like to know the ins and outs of how it works.

How Does the Fusion LED Lighting System Work?

Eager to switch to solar for the savings, but dreading a lengthy installation process or a complicated operating system? Never fear! Making the switch doesn’t have to be laborious or end up being an eyesore, and operation couldn’t be simpler. We’ll break it down step-by-step so that you can see just how easy solar can be with the FUSION LED lighting system. 

First, Waaree solar panels are connected to one another with a rail. Using the iron ridge system, they are racked with legs that affix to the roof and provide stability and support for the panels. Compatible with most roof anchor products, every component in the FUSION system is made with aluminum and stainless steel to ensure complete corrosion resistance, while also resisting the extreme wind and snow forces experienced over a building’s lifetime. 

Next, each solar panel runs two wires- a positive white wire, and a negative black wire- of DC power voltage. The wires from each solar panel are fed into a service head which penetrates through the roof of your building with a 1-2 inch PVC pipe conduit complete with a boot. All wires come through the conduit through the roof and into a control box.

The control box is where all the actual microcontrollers are, giving you easy full access to your complete system. One control box can operate five solar panels. Wiring connections and breakers are housed in the control box as well, with each solar panel wired to two breakers.  Following electrical inspection protocols, 12 gauge MC cables are used for wiring the FUSION LED lighting system. 

Each solar panel is connected to an MC cable which is typically used to power four fixtures (depending on the wattage). The breakers connected to the solar panel distribute DC energy evenly, each breaker powering two light fixtures. In addition, the MC cable that runs the DC power splits at a four-square box at each interior light fixture. There is a regular rubber cord drop from the ceiling to the interior light and DC power is hardwired into the fixture. An access panel at each end of the light fixture provides the connection for both DC and AC power.

At this point, your integrated LED high bay fixtures and troffers for your interior are completed powered by solar during the day. As daylight levels change, AC power controlled by the Genius IoT controller automatically keeps the light output constant.

And just like that, the FUSION LED lighting system is up and running! This Energybank product has been field-tested to work out all the bugs so that you can enjoy a hassle-free experience. There really isn’t a more streamlined or cost-effective way to integrate solar power and LED out on the market. 

How Can I Determine How Many Solar Panels Are Needed?

If you are in the initial research and planning phase of your solar energy project, one of your first questions is likely to be how many solar panels do I need? The answer will be different for each project. The FUSION system has a calculator that operates based on NREL data and how much output you want to reduce.

However, as a general rule of thumb, you can track and consider your wattage usage. A typical Waaree solar panel provides 340-360 watts and output of 36-38 volts. One solar panel powers four of your popular 90-100 watt high bays. You can estimate how many interior high bay light fixtures you would like and then determine the proper amount of corresponding solar panels.

To eliminate the guesswork, collaborate with one of our knowledgeable BizReps associates. We can take a look at your project and consult with you on the appropriate amount of panels needed. 

What Kind of Configurations Are Possible With the FUSION System from Energybank?

Trying to picture exactly what a Fusion LED lighting system looks like? There are several different possible configurations and the right setup will depend on your type of roof and output needs. 

On a metal-style roof, Waaree solar panels are affixed and supported with S5 brackets. There are approximately forty different styles of S5 brackets and the shape of the ridge on the metal roof will determine which style is used for the best fit. The S5 bracket is unique in how its blunt head flat oval type of screws put pressure on the ridge without actually penetrating it. Field testing on the S5 bracket has shown that it is incredibly durable and can withstand extreme weather conditions over time.

The S5 bracket is only a good fit for a metal roof. Flat roofs made of concrete, wood, or rubber require a power grip instead. The bolt on the power grip attaches securely to the iron ridge legs that support the solar panels. 

As far as the solar panels themselves go, Waaree solar panels are the preferred choice for several reasons. First, they come with a 25-year warranty for output and performance guarantee. In addition, they operate at the preferred wattage, 340-360 watts. The output of 36-38 volts matches perfectly with the boards on the FUSION system. 

Typically one control box can power 5 solar panels, however, larger configurations can be customized for your industrial needs. For example, 25 panels could be installed with 5 control boxes.

Interested in the most cost-effective setup of a solar panel system? A 5-panel configuration with a 17 ft rail is the most cost-effective, from a racking standpoint. The next would be a 4-panel configuration with a 14 ft rail. These are the standard sizes in the FUSION system from EnergyBank. Any other configuration would require the rail to be cut to size, which is possible but considerably more expensive. 

To learn more about what type of configuration is the best fit for your business, reach out to a BizReps team member today.

The FUSION LED Lighting System Safety Considerations

The FUSION LED Lighting System was designed specifically with heat safety considerations in mind. The main concern with solar-powered LED lighting is the possibility of overwhelming and overheating the interior light fixtures with too much DC power. Here are a few design components that address this safety concern:

  • The 360-watt solar panel distributes DC power between a minimum of four 90-100 watt high bay fixtures or twelve 40 watt troffers to eliminate the risk of the DC power overheating a fixture.
  • A separate breaker is used for each pair of two light fixtures. If all four light fixtures were on one breaker running to the solar panel there could potentially be a surge from the boards to the light fixtures if one were to go down, and the boards would burn out early.
  • If a fixture is being overpowered or receiving a surge from the boards it will protect itself and the boards by tripping the breaker.

Talk to a BizReps representative today to learn more about important safety considerations when integrating solar with your LED lighting.

What’s the Economic Value of a FUSION System from Energybank?

The 2021 Energy-Efficiency Lighting Guide for Businesses and Building Owners rates the FUSION LED lighting system at the top of its class for economic value. Here are just a few of the major economic benefits:

  • Reduce lighting operating costs by up to 93%
  • Federal Tax Credit eligible as a renewable energy source for the complete FUSION Solar-Powered LED lighting system (labor, lights, solar panel, distribution module, controller, etc.)
  • Eliminate/minimize lighting maintenance costs

Now you know the details of how a solar energy system works and integrates with your LED lighting and can visualize it working for your company. It’s time to take the next steps and move your project forward with this 21st-century business solution. The FUSION LED lighting system from EnergyBank is truly a game-changer! 

Ready to learn more stepping into the future of energy efficiency with solar-powered LED office lighting? Book a call with our team at! We work with companies that are ready to take the next step into better lighting, more efficient lighting that’s going to save money and energy. There are many possible LED lighting solutions that we’re ready to share with you.

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