LIGHTING RETROFIT STRATEGIES AND PROJECT MANAGEMENT TECHNIQUES

1
BASICS OF BALLAST TECHNOLOGY

• Created by the U.S. Department of Energy Rebuild
  America Business Partners
• and
• Advanced Transformer

2
Ballast Design
3
Design Basics
A Rapid Start Ballast Must Perform the Following
Four Functions

• Electrode Preheat Voltage
• Lamp Ignition Voltage
• Regulate Lamp Current
• Regulate Lamp Voltage

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Electrode Voltage

• Heater Voltage Applied Across The Pins of a
  Rapid Start Lamp
• Approximately 3.5 Volts For F40T12, F32T8
• Not Present For Instant Start Lamps
• Heats Electrode to Begin Thermal Emission of
  Electrons
• Voltage Across Pins
• Electrode Current Flow
• Thermal Emission
• Lamp Ready to Start
• .5 to 1 Second

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Lamp Voltage Requirements

• Voltage Applied Across The Lamp
• Ignites The Lamp
• Begins Lamp Current Flow
• 200 Volts For F40T12
• Higher For F32T8
• Higher or Lower Than 120/277 U.S. Line Voltage
• Ballast Acts as a Transformer
• Voltage Must Be Reduced After Lamp Ignition
• 98 Volts for F40T12
• 137 Volts for F32T8

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Fluorescent Lamp Current

• Lamp Will Draw Excessive Current Unless Regulated
• Lamp Failure in 1/100 th of a Second
• Ballast Limits Current Flow
• 430 ma For F40T12
• 265 ma for F32T8
• Maintains Proper Light Output
• Maintains Correct Electrode Temperature
• Too Little Will Decrease Lamp Life
• Too Much Will Decrease Lamp Life

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Starting Methods

• Rapid Start
• Rapid Start - Electrode Cutout (PowrKut)
• Saves 1.5 Watts Per Electrode
• No Reduction in Lamp Life
• Rapid Start - Soft Start
• Ramps Up Ignition Voltage
• Increases Lamp Life
• Exclusive - Advance Mark V/Mark VII
• Instant Start
• No Electrode Voltage, Higher Ignition Voltage
• Possible Lamp Life Reduction if Heavily Cycled
• Highest Efficiency

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Lamp Starting/Circuiting

• Rapid Start Ballasts Generally Have Their Lamps
  Wired in Series
• When One Lamp Burns Out, all Lamps are
  Extinguished
• Instant Start Lamps Generally Have Their Lamps
  Wired in Parallel
• When One Lamp Burns Out, the Remaining Lamps Stay
  On

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Lamp Life

• IES LM-40 Measurement Procedure
• 3 Hours On, 20 Minutes OFF
• Rapid Starting of a RS Lamp will Achieve a 20,000
  Hour Lamp Life
• Instant Starting of a RS Lamp will Reduce Lamp
  Life to 15,000 Hours
• Lamp Life Equal at 12-16 Hours Per Start
• 25,000 to 30,000 Hours
• Occupancy Sensors
• Up to 50 Lamp Life Reduction
• Shorter Life, But in Fixture Same Amount of Time
• Tremendous Energy Savings Potential

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Performance Characteristics

• Ballast Factor
• Input Wattage
• Ballast Efficacy Factor
• Lamp Current Crest Factor
• Power Factor
• Harmonic Distortion
• Electromagnetic/Radio Frequency Interference

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Ballast Factor - Light Output

• Delivered Lumens/Rated Lumens
• 2700/3000 .90 BF
• 2800 rated x .88 BF 2464 delivered lumens
• ANSI Standards
• .925 Minimum for Magnetic
• .85 Minimum for Electronic
• Typical Values
• .95 Magnetic
• .88 - .92 Electronic
• Thermal Effects Allow Difference
• Higher Lamp Bulb Wall Temperature When Operated
  in an Enclosed Fixture Reduces Light Output (and
  Watts)

12
Electronic Ballast Factor Options

• Higher Ballast Factor - Higher Watts
• Lower Ballast Factor - Fewer Watts
• Normal Light Output 85-92 BF
• Reduced Light Output 75-84 BF
• May Cause Lamp Life Reduction
• High Light Output 110-115 BF
• Rated Lamp Current
• Very High Light Output 125- 130 BF
• Will Cause Lamp Life Reduction

13
Efficiency Vs. Efficacy

• Efficiency
• Power Out/Power In
• Ballast Efficiency
• Watts Loss
• Magnetic - 20 W
• EE Mag - 10 W
• Low Freq. Elec. (Hybrid) - 8 W
• High Frequency Elec. - 5-8 W

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Efficiency Vs. Efficacy

• Efficacy
• Un-like Terms
• Lumens/Watt (LPW)
• Miles/Gallon (MPG)
• LPW
• of the Lamp
• of the System

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Input Wattage

• Input Wattage to the Lamp/Ballast SYSTEM
• Separate Wattages are Meaningless
• Different Wattages for Same System
• ANSI
• Open Fixture
• Enclosed Fixture
• ANSI Standard is Only Repeatable Measurement
• Wattage Decrease Follows Light Output
• Manufacturers Catalogs are Different!
• ANSI, Open, Enclosed, ???

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Input Wattage Comparison

• Four Lamp F32T8 Electronic Ballast
• ANSI Input wattage
• 112 Watts
• Open Fixture Wattage
• 109
• Enclosed Fixture Wattage
• 106
• Applicable to 1,2,3,4 Lamp Ballasts
• Two Lamp T8 Electronic
• Advance RS - 60 w ANSI
• Competitor - 60 w OPEN ( equiv. to 62/63W ANSI)
• Same Rated Light Output

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Ballast Efficacy Factor

• Ballast Factor/ANSI Input Watts
• 95BF/96W .99 BEF Magnetic T12
• 90BF/72W 1.25 BEF Electronic T12
• Basis of Legislation
• 1.06 BEF Minimum for (2) F40T12 Lamps _at_120V
• Measurement of Efficacy of Lamp/Ballast System
• Use Lumens per Watt (LPW) to Compare DIFFERENT
  Lamp/Ballast SYSTEMS
• 60 LPW - F40T12 Magnetic System
• 85 LPW - F32T8 Electronic System

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Lamp Current Crest Factor

• Ipeak divided by Irms
• Measurement of Smoothness of Lamp Current
  Waveform
• Sine Wave 1.414
• ANSI Maximum 1.7 Rapid Start
• Typical Magnetic - 1.6-1.7
• Typical Electronic - 1.5-1.6

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Power Factor

• Determines the Relationship Between the Voltage
  and the Current Waveforms
• Normal Power Factor is 50-60
• High Power Factor is gt 90
• Magnetic Ballasts are Typically 95-99 PF
• Electronic Ballasts are Typically 97-99 PF
• No Discernible Difference
• Be Careful of Large Load Reductions!
• Reflectors
• Delamping

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Harmonic Distortion

• Created by Non-Linear Loads
• Computer Power Supplies
• Adjustable Speed Drives
• Arc-Discharge Lighting
• Every Device Except a Resistor
• Magnetic Ballasts Have it
• Electronic Ballasts Have it
• Computers and ASDs Have MUCH MORE!!

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Effects of Harmonic Distortion

• Overheating of Phase Conductors
• Circuit Breaker Tripping
• Transformer Overheating
• Overloading of Neutral Conductor
• A Properly Designed Lighting System Will Cause
  None of This!

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Linear Non-Linear Loads
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Distortion of the Fundamental Waveform with
Harmonic Waveforms
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3 Phase Supply Circuit
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Fundamental (60 Hz) Current Addition
Phase A
Phase B - 120 Degrees
Phase C - 240 Degrees
Fundamental Current Cancels on the Neutral
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Harmonic Current Addition
Phase B - 120 Degrees
Phase A
Triplen Harmonics Add on the Neutral
Phase C - 240 Degrees
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Harmonic Percentages

• ANSI Standard is 32
• IEC Standard is 34.8
• Magnetic Ballast
• Typically 20-30
• Electronic Ballast
• Typically 10-20
• Magnetic Ballasts Draw More Current
• Typical Electronic T8 has 50 Less Harmonic
  Current Than Magnetic T12

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Electromagnetic/ Radio Frequency Interference

• Electronic Ballasts Designed to meet U.S. FCC
  Class A Standards
• Class A Commercial/Industrial Requirements
• 450 - 2000 KHz 60 dB
• 2.0 - 30 MHz 71 dB
• Class B Residential Requirements
• 450 KHz - 30 MHZ 48 dB
• Electronic Ballasts are Class A, and Could
  Interfere with Residential Devices
• Put on Separate Circuits
• Place Farther Away From One Another

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High Frequency Electronic Application Concerns

• Power Line Carrier Systems
• Local RF Transmissions
• Library Book Security Systems
• GFI Circuits
• Infrared Control Devices
• EMI/RFI Sensitive Locations

High Efficiency PowrKut Low Frequency Electronic
Ballasts are Recommended in These Applications.
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System Performance Comparisons
Several Lamp and Ballast Choices

• T8 vs. T10 vs. T12
• Magnetic vs. Hybrid vs. Electronic

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Lamp Comparisons

• F40T12
• 3050Lm/40w 76.3 LPW
• F40T12/34w
• 2750Lm/34w 80.9 LPW
• F32T8
• 2800Lm/32w 87.5 LPW
• 3050Lm/32w 95.3 LPW
• F40T10
• 3700Lm/40w 92.5 LPW

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Ballast Choices

• Magnetic - Operates at 60 Hz
• Hybrid - Electrode Cutout - Operates at 60 Hz
• Electronic - High Frequency - Operates gt20,000 Hz

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Magnetic Ballasts

• Most Common
• Steel
• Copper
• Core Coil
• 60 Hz Lamp Operation
• Lamp Flicker not Noticed
• Audible Noise, Sound Rated A
• Lowest Initial Cost

34
Hybrid Ballasts

• Core Coil
• Electronic Circuit Provides Electrode Voltage
• Electrode Heat Removed After Lamp Ignition
• Saves 1.5 Watts per Electrode
• Electronic Circuit Provides Stable Voltage
• Rated Lamp Life or BETTER
• No Harmful Lamp Effects
• 1.4-1.5 Crest Factor
• 97-99 as Efficient as Electronic Rapid Start
• Lower Initial Cost Than Electronic

35
Electronic Power Flow

• Input
• EMI Filter, Transient Protection
• Rectification
• 60 Hz AC to DC
• High Frequency Converter
• DC to 20,000 Hz AC
• Power Factor Correction
• THD Correction
• Output to Lamp

36
Electronic Ballast

• Operates at High Frequency
• 20,000 Hz to 60,000 Hz
• 6-16 Lamp Efficacy Gain
• Combines Electronic Components with Small
  Magnetic Transformers
• No Fully Electronic Ballast
• Highest Efficiency
• Highest Initial Cost
• No Lamp Flicker
• 25-75 Less Noise

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Electronic Dimming Systems

• Architectural
• 100 - 1 Dimming
• Expensive
• Energy Management
• 100-20 Dimming
• Code Requirements
• 100/50 Step Dimming
• 5 Level Step Dimming

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Energy Management Dimming

• Daylighting
• Occupancy Sensing
• Lumen Maintenance
• Manual Control
• Time of Day Lighting Schedule
• Integrated Building Management System