Convert fluorescent tube to LED. Simple in theory, risky in practice

In industrial maintenance, purchasing, and product development, the question often arises when it comes to converting fluorescent tubes to LED: retrofit or complete replacement? At first glance, retrofit seems attractive: affordable, quick, and without major reconstruction. But upon closer inspection, significant risks emerge – especially in safety-critical areas such as workplace lighting or UV applications.

Retrofit: Economical, but with security gaps

Retrofit LED tubes are designed to fit into existing fixtures. This often involves replacing the starter. What sounds simple hides several pitfalls:

• Live contacts if improperly installed can lead to life-threatening electric shocks.

• Outdated components like sockets or ballasts are not designed for the demands of LED technology, which can additionally cause a fire hazard.

• Lack of compliance with standards due to modifications to the fixture can render certifications like CE invalid.

• Liability and insurance issues arise when modifications are made without manufacturer approval.

It becomes particularly critical when retrofit LEDs are used in workplace lights, UV lights, or safety-critical areas. Here, there are strict requirements for light quality, reliability, and protective mechanisms – requirements that retrofit solutions often do not meet.

Why a complete system change is more sensible

Instead of opting for a retrofit, a complete conversion to a new LED lighting system should be considered in many cases, and for good reasons:

1. Safety

Modern LED systems are fully tested, meet all current standards, and offer integrated touch protection. The risk of electric shock, overheating, or short circuit is drastically reduced.

2. Liability security

CE compliance and manufacturer liability. In case of damage, it is clearly traceable who is responsible.

3. Performance

LED lights are now optimized for a wide range of requirements: whether glare-free light at the assembly table, specific color spectrums in quality control, or UV-stable systems in curing processes. Retrofit can only partially meet these requirements – if at all.

4. Long-term cost-effectiveness

While retrofit tubes appear cheaper at first glance, failures, retrofitting, and maintenance costs add up quickly. A well-thought-out LED complete system is generally more durable, requires less maintenance, and is more energy-efficient – thus more economical in the long run.

Where retrofit is particularly unsuitable

• Workplace lights: Glare-free, color rendition, and light distribution are crucial – retrofit often cannot compete here.

• UV lights: Retrofit LEDs generally do not provide adequate or specified UV output.

• Industrial plants with legacy systems: Old fixtures pose high risks with retrofit applications, particularly if they have been bypassed or rewired multiple times.

Convert fluorescent tube to LED? Not at the expense of safety

Converting to LED is correct and important, but not at any price. In many cases, it is safer, more compliant, and more economical to switch directly to a full-fledged LED system. Those who rely on tested components and proper planning will save money in the long run, reduce downtimes, and protect employees from avoidable hazards.

Opt for complete LED solutions with manufacturer guarantees instead of risky retrofit components. Get advice from professionals, especially when it comes to workplace lighting or sensitive applications.

Do you want to future-proof your lighting? We are happy to advise you – neutral, practical, and compliant.