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Ballast Basics II
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Fluorescent Ballast Basics II
• • •
Advanced Ballast Definitions Standards & Regulations Lighting Retrofits & Energy Savings
Note: Ballast Basics I Should be Completed Prior to Beginning this Section
© Universal Lighting Technologies | 2
Course Benefits
When you complete this course, you will have learned:
Understanding Power Factor Total Harmonic Distortion (THD) and How it is specified Ballast Standards and Regulations T8 Retrofit Wiring Connections 3 rd Party requirements important to your customer Reducing energy costs by retrofitting ballasts Examples of common retrofits © Universal Lighting Technologies | 3
Power Factor
Power factor indicates how efficiently the power from the utility is being utilized. The higher the power factor, the less current is needed to provide the same amount of power. A high power factor ballast allows for more ballasts on a circuit. Also, utilities have penalties for facilities with low power factors since it requires more current to be generated.
The formal equation:
PF = Actual Power (Watts)/Apparent Power (Volts x Amps) Example:
120 Watts of lighting @ 120V with PF=.99
120 Watts of lighting @ 120V with PF=.60
Input Current = 1 amp Input Current = 1.66 amps
More current required for the same power
A power factor equal to or above .90 is considered High Power Factor
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Total Harmonic Distortions (THD)
• THD is a measurement of the harmonic content in the current a piece of equipment draws from the power line. THD is percentage value.
•High Harmonic Values can: • •
Result in Large Neutral Currents in 3-phase Systems
– Potential for overheating neutral conductors
Cause Voltage distortion problems t rr e u C
30 20 10 0 0 -10 -20 -30
Harmonic Current
90 180 270 360 The distorted line represents a current wave shape with 17% THD versus a pure sinusoid wave shape with no THD © Universal Lighting Technologies | 5
Total Harmonic Distortions (THD) Cont.
System Retrofit Analysis with effect on THD
Lighting System Before a Retrofit
– 2 lamp magnetic ballast with F34T12 lamps – – Ballast THD = 20%, Watts = 74W, I = .65A
Harmonic Current .20 x .65 = .13A
New Electronic Lighting System after Retrofit
– 2 lamp Electronic “L” ballast with F32T8 lamps – – THD = 20%, Watts = 51W, I = .44A
Harmonic Current .20 x .44 = .088A
This Retrofit with an Electronic Ballast Provides approximately a
32%
Reduction in Harmonic Current and in Power consumption © Universal Lighting Technologies | 6
THD: Typical Values
• • • •
Electro Magnetic Ballasts: ANSI Commercial Ballast Requirement: Universal’s HP Family: Typical screw-in CFL’s:
Less than 30% Less than 32% Less than 10% Greater than 100%
Typical specified THD Levels are either less than 10% or less than 20%. Requirements for ballasts to meet ANSI requirements allows for THD values to be just less than 32%.
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Starting Temperatures
Minimum starting temperature is both ballast and lamp dependent
– See ballast label for specifics (std. is 50⁰F (10⁰C) for most magnetic ballasts) – Energy saving lamps do not function well below 60⁰F (16⁰C), including the newer 25, 28, and 30-Watt T8 lamps
Many electronic ballasts are designed for 0⁰F (-18⁰C) or -20⁰F (-29⁰C) starting Magnetic High Output: -20⁰F (29⁰C) In low temperature applications, it is important for the lamps to heat up to generate sufficient light output.
– Lamp Jackets are typically used in these applications so that the heat that the lamp generates is used to heat the lamp rather than to dissipate into the outside air.
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Remote Mounting
• •
Remote Mounting Distance Definition:
Maximum allowable length of the ballast lead wire from the ballast to the lamp socket.
Typical remote mounting distances: – Instant Start: 18’ with full wattage lamps – Programmed Start lamp: 20’ with full wattage lamps – Instant Start & Programmed Start: 6’ with ES lamps – Consult specification sheets for specific ballasts
Ballasts are limited in how far they can be mounted from the lamps they are
operating. •For electromagnetic ballasts, larger gauge wire is necessary to compensate for longer distances as voltage drops from the leads. • For Electronic ballasts, high frequency interactions between the leads and conduit reduce the ballast output voltage. For electronic ballasts, a maximum distance is specified by the ballast manufacturer.
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Shut Down Circuits
End of Lamp Life (EOL)
When lamps with a bulb diameter of T5 or less are operated on high frequency electronic ballasts without EOL sensing circuitry, one or both of the following scenarios may occur at end-of-lamp-life:
1. Glass cracking near lamp base
(The filament opens and touches the glass)
2. Overheating or melting of lamp base or socket
(Lamp rectifies at the end of life and generates significant heat at the filaments and socket) Many ballasts now include shutdown circuits that sense when the lamp is at its end of life and will shut down power to the lamps to prevent the undesirable failure modes © Universal Lighting Technologies | 10
UL Listed
Underwriters Laboratory
• UL 935: Fluorescent-Lamp Ballasts Standard
Safety Requirement
•
Assure proper ratings on labels
• • – – Lamps Approved Maximum Input current ratings – Input & Output Voltages
Requires passing of various tests for safe operation, including….
– Faults are induced within the ballast to confirm that the ballast fails safely – – Tests for shock hazard potential during lamp replacements Confirms case temperatures are within limits
Requires 100% production tests for insulation/isolation from internal components and lead wires
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New DOE Ruling for 2014 (BLE)
The Energy Policy & Conservation Act (EPCA) was signed into law on November 14, 2011. As part of this larger Ballast Rule, a new linear fluorescent efficiency standard became law on January 13, 2012.
The new efficiency manufacturers is called measurement standard for
BLE (Ballast Luminous Efficiency)
and replaces the older Ballast Efficacy Factor (BEF) metric.
This law comes into enforcement on November 14, 2014.
This grace period allows manufacturers to make the necessary changes in design to meet the new efficiency standards.
After this date, the government will prohibit the domestic manufacture and importation of products that don’t meet the new standards.
This will not affect the sale of any completed units in inventory.
Existing inventories can be sold until they are consumed.
This new DOE 2014 Ballast Rule requires higher efficiency in many of today’s linear fluorescent ballasts. It will affect nearly all non-dimming ballasts for linear lamps in the 120 – 277 volt range.
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Legislation Shift to Efficiency
New efficiency requirements will continue to drive the market to higher efficiency T5, T8, dimming, demand response, and LED solutions.
Why did DOE change the efficiency metric?
The metric, since 1984, has been Ballast Efficacy Factor (BEF). In 2011, the Ballast Luminous Efficiency (BLE) metric was created. Unlike BEF, BLE is based solely on electrical measurements and removes variability by measuring true power in and true power out of the ballast. BLE shows the losses inside the ballast only.
What are the advantages of using BLE?
• Clear view of ballast performance – lamp is only a load • No photometrics are needed – only electrical measurements • No reliance on lamp efficacy • • Measurement is repeatable and reliable, minimizes error due to photometrics More accurate measurement of ballast efficiency • Ballast is measured warm, as actual operation use condition, giving true picture of steady state performance © Universal Lighting Technologies | 13
Coverage, Requirements, & Exceptions
The new Ballast Rule encompasses more ballasts than ever before. Previously, only ballasts that operated one or two T12 lamps needed to be measured and reported to DOE. The new rule covers almost all T5, T8 and T12 ballasts.
Coverage:
– Manufactured on or after November 14, 2014 – – – – Manufactured in, or imported into, the United States Operate nominal input voltages at or between 120V and 277V.
Includes sign ballasts Includes residential ballasts
Requirements:
– Non-residential ballasts: Power Factor ≥ 0.90
– – Residential ballasts: Power Factor ≥ 0.50
Residential ballasts: FCC 47CFR Part 18 consumer limits • Designed, labeled, marketed – Sign ballasts: UL Type 2 rating • Designed, labeled, marketed – All ballasts must meet BLE standard
Exceptions:
– 347V and 480V ballasts – Export ballasts (must be labeled) – Dimming ballasts designed to dim to 50% or less of max output – Magnetic T8 ballasts for EMI-sensitive environments (must be labeled) – Low BF (.71) programmed start ballasts that operate 4’ T8 lamps © Universal Lighting Technologies | 14
Retrofit Energy Savings
Electronic ballasts are commonly used in lighting retrofits where magnetic ballasts with T12 lamps are removed from lighting fixtures and replaced with electronic ballasts and T8 lamps. The key reason for this is the significant financial savings that result from these energy saving retrofits although there are numerous other lighting benefits that are achieved.
To Calculate the financial savings, the following information is needed:
• • • • •
Existing lighting fixture’s input power Replacement system’s input power Annual hours of operation Utility rate Quantity of lighting fixtures
Input power values are available from ballast manufactures catalogs or specification sheets
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Retrofit Energy Savings Equations
Energy Savings = Existing Wattage – New Wattage Annual Utility Savings per Fixture: Energy Savings (Watts) x Annual Operating Hours x Utility rate ($/kWH) 1000 (for conversion of units) Annual Utility savings ( $’s) © Universal Lighting Technologies | 16
Retrofit Example (Continued)
System Lumens Example
Ballast Type Lamp Rated Lamp Lumens x Ballast Factor x Number of Lamps System Lumens Magnetic Electronic "EL" F34T12 F32T8
2280 x 0.90
x 4
8208
2710 x 0.78
x 4
8455
Energy Savings Example
Input Watts 148 watts 98 watts
Savings = 50W x 4000 hours per year x .06$/kWH / 1000
Savings = $12.00 per year Maximize energy savings by not over lighting
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Retrofit Wiring Connection
Electromagnetic to Electronic
Magnetic Rapid Start to Electronic Programmed Start – No wiring changes for 1 & 2 Lamp Models – 3 & 4 lamp models will combine lamp pairs – Two wires connect to each lamp socket Magnetic Rapid Start to Electronic Instant Start – – – Simple wiring changes Lamp sockets are effectively shorted out Fewer connections than rapid start wiring Existing lamp sockets within the fixture are not moved or replaced unless their condition warrants replacement.
© Universal Lighting Technologies
Rapid Start to Instant Start
Wiring – 2 Lamp
Line Yellow Yellow BALLAST Blue Blue Red Red
Existing leads are tied together and connected to new ballast leads which connects both sides of a filament with itself for proper operation
Magnetic T12 Rapid Start Wiring
Line Red Blue BALLAST Blue Yellows Yellows Reds Blues
Electronic T8 Instant Start Wiring
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Rapid Start to Instant Start
Wiring – 4 Lamp Existing lead pairs from the magnetic ballasts are tied together and connected to a single lead of the same color from new electronic ballast. One four lamp electronic ballast can replace two 2-lamp magnetic ballasts.
Line Yellows Yellows Yellows Yellows
Lamps from 2 nd ballast magnetic Lamps from 1st magnetic ballast
Yellow Yellow BALLAST Blue Red Blue Red Reds Blues Reds Blues © Universal Lighting Technologies | 20
Magnetic High Bay HID Lighting
Issues
High energy consumption
• Better than Incandescent but they still use significant amounts of power
Warm-up & Re-strike delays
• Lamps do not come on instantly and will take a few minutes to attain full brightness • HID lamps cannot effectively connect to occupancy sensors because of the warm-up and restrike delays
Magnetic HID ballasts generate noise
• These are not conducive to many applications
Poor lumen maintenance
• HID lamps significantly decrease in lumen output over time • 65% Lumens at 40% of rated life
Poor Color Rendering Index (CRI) values
• Low CRI values reduces the color quality of the light • HID lamps color vary over time from lamp to lamp.
Most HID High Bay fixture efficiencies are poor, < 80%
• Fixtures do not effectively reflect light out of the fixture © Universal Lighting Technologies
High Lumen Fluorescent
HID Alternative Lighting Solutions
Energy efficient
•Over 30% saving in utility costs over magnetic HID
Instant on with no warm-up time
•Lamps will turn on immediately with full brightness •Compatible with occupancy sensors for maximum energy savings since there are no warm-up or restrike delays
Quiet operation
Applications:
•Sound rated A, ideal for retail, schools, etc.
Excellent Lumen Maintenance
•
Warehouses
•Gymnasiums •90-95% Lumens at 40% rated life •Light levels remain fairly consistent over time
Excellent color
•
Big Box Retail
•
Industrial
•CRI values typically 75 to 85 •No color variance or shift over time
Fixture efficiencies are greater than 90%
•New High Bay fluorescent fixtures are extremely efficient compared to the common HID High Bay fixtures © Universal Lighting Technologies | 22
Lamp Temperatures
High Bay Applications
Note: Fluorescent lamps are very temperature dependent while HID lamps provide fairly constant light output across all temperatures
•Fluorescent lamps have identified ambient temperatures where they provide maximum light output •For extreme cold temperatures, fluorescent lamps might not be suitable unless the lamp is jacketed or the fixture is designed to retain heat
T5HO Optimal Temperature
•35 ° C (95 ° F) Ambient
T8 Optimal Temperature
•25 ° C (77 ° F) Ambient 105 100 95 90 85 80 75 70
Light Output vs. Temperature
T8 Lamps T5HO Lamps 20 25 30 35 40
Ambient Temperature (°C)
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T5HO High Bay Fluorescent
T5HO Lamps (F54T5HO)
•
Provides the most light with the fewest lamps
• 4-Lamp T5HO fixtures are frequently used to replace 1-400 Watt Metal Halide HID fixture • 6-Lamp T5HO fixtures increase light levels but still save energy over 400 Watt fixtures
Programmed Start:
• Ideal for use with occupancy sensors • Maximizes lamp life in frequently switched applications • T5HO Lamps are at maximum light levels in 35 ° C (95 ° F) ambient temperatures •
Ballasts are available for 120, 277, 347, and 480 volt applications
© Universal Lighting Technologies
HID to T5HO Lumen Comparisons
HID TO T5HO LUMEN COMPARISONS -
LIGHT OUTPUT OVER TIME
400 Watt Metal Halide fixtures start with the highest delivered lumens but due to poor lumen maintenance, their light levels drop off significantly over time.
4-Lamp and 6-Lamp T5HO fixtures light levels remain fairly consistent and at the same time, operate with lower input Watts 30,000 26,000 22,000 18,000 14,000 10,000 0 2 4 6 8 10 12 14
Operating Hours (1,000's)
16 18 20
Delivered system lumens uses HID fixture efficiency of .80 & Fluorescent fixture of .92
Less Lumen depreciation allows for better designs for specific applications
Std 400W MH (458 Watts) 6-Lamp T5HO (339 Watts) 4-Lamp T5HO (226 Watts) © Universal Lighting Technologies | 25
T5HO Retrofit Example
Warehouse conversion from HID to Electronic T5HO
Additional Benefits:
•Improved Lighting •Uniform Illumination •Color •Less Glare •Instant on Capabilities •Ability to control Lamps with Occupancy Sensors Fixture Type Existing Installation 400W Metal Halide New Installation 4-Lamp T5HO w/ Instant Start Ballast # of Fixtures 209 209 4500 Annual Operating Hours $0.08
Utility Rate ($/KWH) Fixture Wattage 458 Annual Operating Cost $34,460 226
Savings
$17,004
$17,456 Savings Calculation
458- 226 = x x ÷ = x 232 Watts saved/fixture $0.08 KWH 4500 Annual operating hours 1000 KW to W conversion $83.52 Annual savings per fixture 209 Fixtures = $17,455.68 Annual lighting system savings © Universal Lighting Technologies | 26
T8 High Bay Fluorescent
T8 Lamps (F32T8)
•Most common lamp for electronic ballasts – This same lamp is probably used elsewhere in the same facility •Variety of lamp options available • Colors, CRI’s, life ratings, energy saving lamp options, etc.
•High Ballast Factor (HEH) ballasts used for High Lumen applications • Ballast Factor of 1.18 to maximize light output from the lamp • Programmed Start & Instant Start products available • Programmed Start: • Ideal for use with occupancy sensors • Maximizes lamp life in frequently switched applications • Instant Start: • Maximizes energy savings for long cycle applications •T8 Lamps are at Maximum light output at 25 degrees C (77 degrees F) ambient temperatures •Ballasts are available for 120, 277, 347, and 480 volt applications © Universal Lighting Technologies | 27
HID to T8 Lumen Comparisons
Light Output over Time
400 Watt Metal Halide fixtures start with the highest delivered lumens but due to poor lumen maintenance, their light levels drop off significantly over time.
4-Lamp and 6-Lamp T8 fixtures light levels remain fairly consistent and at the same time, operate with lower input Watts 6-Lamp fixture is the common T8 replacement of 400 Watt MH HID fixtures
6-Lamp T8 provides lower initial lumens but higher maintained lumens
30,000 26,000 22,000 18,000 14,000 10,000 0 2 4 6 8 10 12 14
Operating Hours (1,000's)
16 18 20
Delivered system lumens uses HID fixture efficiency of .80 & Fluorescent fixture of .92
Std 400W MH (458 Watts) 6-Lamp T8 (226 Watts) 4-Lamp T8 (154 Watts) © Universal Lighting Technologies | 28
T8 Retrofit Example
Gymnasium conversion from HID to Electronic T8
• • • •
Additional Benefits:
Quiet Operation Improved Color Instant On Ability to control Lamps with Occupancy Sensors Existing Installation Fixture Type 400W Metal Halide New Installation 6-Lamp T8 # of Fixtures 38 38 Fixture Wattage 458 Annual Operating Cost $4,873 226
Savings
$2,405
$2,468
3500 Annual Operating Hours $0.08
Utility Rate ($/KWH) 458- 226 = x x ÷ = x =
Savings Calculation
232 Watts saved/fixture $0.08 KWH 3500 Annual operating hours 1000 KW to W conversion $64.96 Annual savings per fixture 38 Fixtures $2,468.48 Annual lighting system savings © Universal Lighting Technologies | 29
Incentive Programs
Demand Response Programs
The rising demand for energy has resulted with an increasing number of utilities implementing Demand Response (DR) programs. Consumers in these markets will be demanding manual or automatic dimming and energy management lighting controls to take advantage of the incentives offered, as well as to avoid associated Peak Demand charges.
Energy Incentive Rebate Programs
Many state and utility rebate programs moving away from standard lighting upgrades and toward controllable systems. Example: National Grid – Non-Residential Energy Efficiency Program Eligible Technologies: Lighting, Lighting controls/sensors Amount: Linear Dimming Fixtures: $15-50/fixture, Lighting Sensors: $20-60/sensor © Universal Lighting Technologies | 30
DSIRE Database
For a list of rebates and energy incentives by state visit the Database of State Incentives for Renewables and Efficiency (DSIRE) website. Universal’s website links to the DSIRE Database: http://www.dsireusa.org/ Click the state in question to view the available energy rebates.
Select the state or utility rebate program for your area/ DSIRE summarizes the rebate program offering, and has a link directly to the program’s site for more information. © Universal Lighting Technologies | 31
Potential $ales
Target Customers that still use T12 lamps
• Promote energy efficiency by selling the energy savings of an electronic T8 lighting retrofit – Generate new ballast and lamp sales • Easy to use energy saving calculation programs are available from your Universal sales representative or agent
Additional Incentives for Customers
• Local utilities may be offering rebates for energy saving lighting upgrades or retrofits • Tax deductions are available if requirements are met © Universal Lighting Technologies | 32
THANK YOU
For Additional Information, please visit our website www.unvlt.com.
Website: www.unvlt.com
Nashville Customer Service: (800) 862-8666 Universal Technical Engineering Services: 1-800-BALLAST (1-800-225-5278) © Universal Lighting Technologies | 33