200-480VAC Direct Connect
— No Step-Down Transformer Required
PLB Series for industrial ground-level poles (15–30ft): DIP selectable 75–300W · 10kV/5kA surge · OSHA & IES RP-7 ready
200-480V
Direct Industrial HV
10kV/5kA
Surge for EMI
44,429 lm
Max @300W @5000K
6 Wattages
DIP in 2 Housings
The PLB Series is a shoebox-form-factor area light purpose-built for ground-level pole mounting at 15–30ft heights — covering industrial roads, walkways, loading areas, and perimeter fencelines. The 200-480VAC high-voltage driver option connects directly to industrial 480V/3-phase power systems, eliminating step-down transformers that add $800–1,500 per pole in hardware, 2–4 hours of installation time, and a recurring maintenance liability. With 10kV/5kA surge protection — 67% above the industry standard — PLB survives the transient spikes from VFDs, welders, and heavy motor starters common in manufacturing and logistics facilities. DIP switch selection across 6 wattages (75–300W) means one fixture order covers fenceline, road, and staging area requirements. For high-mast applications above 40ft or crane-serviced yards, see our OT Gen 1 high-mast guide.
Why PLB for Industrial
PLB Series vs Standard Commercial Shoebox in Industrial Environments
Standard commercial shoebox fixtures fail in industrial environments for three reasons: they can't handle 480V power, they lack adequate surge protection for EMI-heavy sites, and they require separate SKUs for every wattage level across zones. PLB solves all three.
| Requirement | Standard Shoebox | PLB Series | Industrial Impact |
|---|---|---|---|
| Voltage Range | 120-277VAC only | 100-277V + 200-480VAC | No transformer needed ✓ |
| Surge Protection | 6kV/3kA | 10kV/5kA | Survives VFD/welder spikes ✓ |
| Wattage Flexibility | 1 wattage per SKU | 3 wattages per housing (DIP) | 1 order covers 3 zones ✓ |
| Max Output @5000K | ~35,000 lm | 44,429 lm @300W | Fewer fixtures per zone ✓ |
| CCT Selection | Fixed per SKU | DIP 3000K/4000K/5000K | 5000K for safety, 3000K at perimeter ✓ |
| Efficacy | 130–150 lm/W | Up to 180 lm/W @4000K | Lower energy cost per fc ✓ |
| IP / IK | IP65 / IK08 | IP65 / IK08 | Equivalent |
| Transformer Cost | $800–1,500/pole | $0 | Eliminates #1 hidden cost ✓ |
“Standard Shoebox” based on published specs from major manufacturers at comparable wattage ranges (2024–2025 catalogs).
What We Hear
4 Industrial Lighting Problems PLB Eliminates
“Every pole in our facility runs on 480V 3-phase. Installing 277V shoebox fixtures means adding a step-down transformer at every single pole — that's $1,200 in hardware plus 3 hours of electrician time per location. On 40 poles, that's $48,000 just in transformers before we even buy the fixtures.”
— Plant Manager, automotive parts manufacturing facility, Detroit MI✅ PLB Fix: 200-480VAC driver option connects directly to 480V/3-phase. Zero transformers. $48,000 saved on a 40-pole site.
“We had three LED fixture failures in 6 months — all on the building adjacent to the VFD room. The vendor blamed ‘power quality issues’ and voided the warranty. Our electrician confirmed voltage spikes from the drives were killing the drivers.”
— Safety Officer, food processing plant, Central Valley CA✅ PLB Fix: 10kV/5kA surge protection — 67% above the 6kV/3kA industry standard. Built to absorb transients from VFDs, welders, and heavy motor starters.
“Procurement approved one PO for all outdoor lighting. But we need 75W for the fence line, 150W for internal roads, and 300W for the truck staging area. That's three different fixtures, three lead times, and three chances for the wrong product to show up.”
— Procurement Manager, logistics & distribution center, Memphis TN✅ PLB Fix: Order 150W housings for fenceline (DIP to 75W) and 300W housings for roads/staging (DIP to 150–300W). 2 SKUs, 1 PO, all zones covered.
“The spec says 5 foot-candles minimum across the entire yard for OSHA compliance. But half the poles have 20ft mounting height and the other half are 30ft. The photometric layout needs different wattages at every other pole — that's an inventory nightmare.”
— Electrical Contractor, petrochemical facility retrofit, Houston TX✅ PLB Fix: Install 300W housings on all poles. DIP to 200W on the 30ft poles, 300W on the 20ft poles. Same fixture, tuned per pole height during commissioning.
IES Verified Performance
Full IES Data — All 6 Wattages at Industrial CCTs
All data from IES files and LM-79-19 test reports. Type IV (T401) optic. Every wattage achieves U0 zero uplight. 5000K is recommended for industrial safety/visibility.
@5000K (Daylight) — Recommended for Industrial
| Wattage | Lumens | Efficacy | DIP Housing | Industrial Zone | Uplight |
|---|---|---|---|---|---|
| 75W | 12,594 lm | 172 lm/W | 150W Housing | Fenceline / Perimeter | U0 |
| 100W | 16,068 lm | 164 lm/W | 150W Housing | Walkways / Pedestrian | U0 |
| 150W | 22,190 lm | 150 lm/W | 150W Housing ★ Roads | Internal Roads | U0 |
| 200W | 32,806 lm | 163 lm/W | 300W Housing | Wide Roads / Intersections | U0 |
| 250W | 38,830 lm | 155 lm/W | 300W Housing | Loading / Dock Areas | U0 |
| 300W | 44,429 lm | 147 lm/W | 300W Housing ★ Staging | Truck Staging / Yards | U0 |
@4000K (Neutral) — Peak Efficacy CCT
| Wattage | Lumens | Efficacy | DIP Housing | Uplight |
|---|---|---|---|---|
| 75W | 12,762 lm | 180 lm/W ★ Peak | 150W Housing | U0 |
| 100W | 16,473 lm | 175 lm/W | 150W Housing | U0 |
| 150W | 23,505 lm | 167 lm/W | 150W Housing | U0 |
| 200W | 33,645 lm | 175 lm/W | 300W Housing | U0 |
| 250W | 40,463 lm | 170 lm/W | 300W Housing | U0 |
| 300W | 46,950 lm | 165 lm/W | 300W Housing | U0 |
Source: IES files and LM-79-19 test reports. Type IV (T401) optic. All wattages confirm U0 zero uplight.
Industrial CCT recommendation: 5000K
While 4000K delivers the highest efficacy (up to 180 lm/W), 5000K is recommended for industrial outdoor areas because it provides better visual acuity for hazard detection, higher contrast for safety signage and PPE identification, improved CCTV image quality, and reduced fatigue during extended outdoor shifts. The efficacy difference is modest: 172 lm/W @75W @5000K vs 180 lm/W @4000K — a 4.4% trade-off for significantly better safety outcomes.
Compliance Standards
OSHA 1926.56 & IES RP-7 — Industrial Outdoor Lighting Requirements
OSHA 1926.56 — Minimum Illumination Standards
| Area Type | OSHA Min (fc) | PLB Recommended | PLB Config |
|---|---|---|---|
| General site areas | 3 fc | 5–8 fc (safety margin) | 75–100W @5000K, 15–20ft poles |
| General construction / industrial ★ | 5 fc | 8–12 fc (safety margin) | 150–200W @5000K, 25ft poles |
| Concrete placement, excavation, loading | 10 fc | 12–20 fc (safety margin) | 250–300W @5000K, 25–30ft poles |
| First aid stations, offices, shops | 30 fc | Interior — not PLB scope | N/A |
IES RP-7 — Industrial Lighting Practice
| Industrial Area | Recommended (fc) | Uniformity | PLB Config |
|---|---|---|---|
| Yard areas — inactive storage | 1–2 fc | 4:1 | 75W @5000K, Type III |
| Yard areas — active material handling | 5 fc | 3:1 | 150W @5000K, Type IV |
| Roadways — plant internal | 2–5 fc | 4:1 | 100–150W @5000K, Type IV |
| Loading/unloading platforms ★ | 10–20 fc | 3:1 | 250–300W @5000K, Type IV/V |
| Entrance gates / guard stations | 5–10 fc | 3:1 | 150–200W @5000K, Type V |
Sources: OSHA 1926.56(a) Table D-3; IES RP-7-17 “Practice for Industrial Lighting”
Field Adjustable
DIP Switch Guide — Wattage by Industrial Zone
DIP switch wattage selection eliminates the most expensive industrial lighting mistake: ordering separate fixtures for every zone when one housing can cover three wattage levels.
⚡ 150W Housing — Perimeter & Walkways
Fenceline & perimeter security
12,594 lm @5000K · 15ft poles · 60ft spacing
Pedestrian walkways & break areas
16,068 lm @5000K · 18ft poles · 55ft spacing
Secondary roads & employee parking
22,190 lm @5000K · 20ft poles · 70ft spacing
🔥 300W Housing — Roads & Staging
Primary internal roads
32,806 lm @5000K · 25ft poles · 90ft spacing
Loading docks & material handling
38,830 lm @5000K · 25ft poles · 80ft spacing
Truck staging & container yards
44,429 lm @5000K · 30ft poles · 100ft spacing
Commissioning Workflow
- 1Install all fixtures with default DIP setting (highest wattage per housing)
- 2Run photometric verification with light meter at ground level
- 3DIP down over-lit zones to lower wattage — saves energy, extends fixture life
- 4Document final DIP settings per pole for maintenance records
Photometrics
Optic Types for Industrial Zone Coverage
Industrial facilities have distinct zones requiring different distribution patterns. PLB's three optic types — Type III, IV, and V — allow designers to optimize each zone independently while using the same fixture platform.
Type III
T301 — Perimeter & Fenceline
Forward throw with minimal backlight. Prevents light trespass beyond property line. Ideal for fenceline poles where spill light causes neighbor complaints or regulatory issues.
Type IV
T401 — Roads & Staging
Wide asymmetric forward throw. The primary optic for internal roads, truck routes, and staging areas. 3–4× mounting height spacing. Workhorse for industrial layouts.
Type V
T501 — Intersections & Gates
Symmetric 360° spread. Use at road intersections, guard stations, entrance gates, and equipment staging circles where vehicles approach from all directions.
✓ Zero uplight — all configurations
Every PLB configuration achieves U0 zero uplight. For industrial facilities near airports or in municipalities with light pollution ordinances, PLB's full-cutoff shoebox housing ensures compliance without additional shielding accessories.
ROI Analysis
Energy & Cost Savings — PLB vs HPS in Industrial
PLB 300W @5000K vs 1000W HPS (Industrial Yard)
| Metric | 1000W HPS | PLB 300W | Savings |
|---|---|---|---|
| System wattage | 1,080W (incl. ballast) | 300W | 72% reduction |
| System lumens | ~33,000 lm (initial, degrading) | 44,429 lm @5000K (maintained) | +35% more lumens |
| Annual kWh (16hr/day — industrial) | 6,307 kWh | 1,752 kWh | 4,555 kWh |
| Annual electricity ($0.12/kWh industrial) | $757 | $210 | $547/fixture |
| Maintenance/year | $250 (lamp + ballast + bucket truck) | $0 | $250 |
| Transformer cost (480V→277V) | $1,200/pole (amortized $120/yr) | $0 (200-480VAC direct) | $120/yr eliminated |
| Total annual savings | — | — | $917/fixture/year |
$0
Step-Down Transformers
200-480VAC direct connection. $800–1,500 per pole eliminated.
72%
Wattage Reduction
300W PLB replaces 1,080W HPS system with 35% more lumens.
$0
Lamp/Ballast Maintenance
No relamping. No ballast replacement. No bucket truck rentals.
40-pole industrial facility: $36,680/year total savings. With DLC rebate of $50–200/fixture, typical payback period under 12 months. For facilities running 24/7 (ports, distribution centers), payback can be under 9 months.
Spec Guide
Recommended PLB Configurations by Industrial Zone
| Zone | Housing | DIP Wattage | Optic | Pole Height | CCT |
|---|---|---|---|---|---|
| Fenceline / Perimeter | 150W Housing | 75W | Type III | 15ft | 5000K |
| Pedestrian Walkways | 150W Housing | 100W | Type IV | 18ft | 5000K |
| Internal Roads ★ Most Common | 150W or 300W | 150W or 200W | Type IV | 20–25ft | 5000K |
| Loading Docks | 300W Housing | 250W | Type IV | 25ft | 5000K |
| Truck Staging / Container Yards | 300W Housing | 300W | Type IV | 30ft | 5000K |
| Gate / Guard Stations | 300W Housing | 200W | Type V | 25ft | 5000K |
| Employee Parking | 150W Housing | 100–150W | Type IV + Type III | 20ft | 4000K |
⚠️ High-Mast & Crane-Serviced Yards → OT Gen 1
PLB is optimized for ground-level poles at 15–30ft mounting heights. For high-mast applications above 40ft, crane-serviced container yards, port facilities, or large open staging areas requiring 80–120ft mounting heights, we recommend the OT Gen 1 high-mast LED flood — designed for extreme throw distances, high-vibration mounts, and fixture counts per mast head. Many industrial facilities use PLB for roads/walkways + OT Gen 1 for high-mast yards as a combined solution.
Compliance
Certifications & Industrial Compliance
UL 1598 Listed
Listed for wet locations. Outdoor pole/arm-mounted luminaires.
✓ UL Listed — all PLB models
DLC Qualified
Utility rebate eligible. $50–200/fixture from most US utility programs.
✓ All PLB Series models
LM-79-19 Tested
Independent photometric testing per IES LM-79-19 standard.
✓ Full IES files available for all wattages
OSHA 1926.56 Ready
Meets minimum illumination standards for industrial/construction areas.
✓ 5–300W range covers 3–10+ fc requirements
IES RP-7 Compliant
Meets Practice for Industrial Lighting recommendations with proper layout.
✓ Optic selection enables uniformity targets
10kV/5kA Surge
Enhanced surge protection for industrial EMI environments.
✓ 67% above typical 6kV/3kA — survives VFD spikes
200-480VAC Option
Direct connection to 480V/3-phase industrial power. No transformer.
✓ Eliminates $800–1,500 per pole in transformer cost
IP65 / IK08
Dust-tight and water jet resistant. IK08 impact protection.
✓ Suitable for harsh industrial environments
FCC Part 15
EMI compliance — PLB won't interfere with industrial SCADA/radio systems.
✓ FCC Part 15 Class B certified
Frequently Asked
PLB Series Industrial Ground Lighting — FAQ
Can the PLB Series run on 480V industrial power without a step-down transformer?
Yes. PLB Series is available in a 200-480VAC high-voltage driver option that connects directly to 480V/3-phase industrial power systems. This eliminates the need for step-down transformers — removing $800–1,500 per transformer in hardware cost, reducing installation time by 2–4 hours per pole, and eliminating a common point of failure in industrial outdoor lighting systems.
How does PLB meet OSHA industrial lighting requirements?
OSHA 1926.56 requires minimum 5 foot-candles for general construction/industrial areas and 3 foot-candles for general site areas. PLB's 200–300W configurations at 5000K deliver 32,806–44,429 lumens per fixture, providing more than sufficient illumination for OSHA compliance on 20–30ft poles spaced at standard intervals. The 10kV/5kA surge protection ensures reliable operation in EMI-heavy industrial environments near VFDs, welders, and heavy switchgear.
What wattage should I use for different industrial zones?
Fencelines and perimeter walkways: 75W (12,594 lm @5000K) on 15ft poles at 60ft spacing. Internal roadways and truck routes: 150W (22,190 lm @5000K) on 25ft poles at 80ft spacing. Loading docks and staging areas: 300W (44,429 lm @5000K) on 30ft poles at 100ft spacing. DIP switch adjustment means you can order all 300W housings for road/staging areas and tune wattage during commissioning.
Why is 5000K recommended for industrial instead of 4000K?
While 4000K delivers the highest efficacy (up to 180 lm/W), industrial safety standards and OSHA guidance favor 5000K for outdoor areas because: (1) higher visual acuity for hazard detection, (2) better contrast for reading signage, markings, and PPE colors, (3) improved camera/CCTV image quality for security, and (4) reduced fatigue during extended outdoor shifts. The efficacy trade-off is modest — 172 lm/W @75W vs 180 lm/W @4000K.
How does the PLB handle EMI interference from industrial equipment?
PLB's 10kV/5kA surge protection is 67% higher than the typical 6kV/3kA rating on standard commercial fixtures. This is critical in industrial environments where variable frequency drives (VFDs), arc welders, large motor starters, and capacitor bank switching generate transient voltage spikes on the power line. The built-in SPD (surge protective device) absorbs these spikes before they reach the LED driver, preventing premature failure. FCC Part 15 Class B compliance also ensures the PLB's own electronics don't generate interference.
PLB Series — Industrial
Ready to Spec PLB for Your Industrial Facility?
Get a free photometric layout for your industrial site, compare 200-480VAC configurations, or request a quote. Our team responds within 1 business day.