Ballast Basics II

1. Ballast Basics II

2. 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

3. 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 • 3rd Party requirements important to your customer • Reducing energy costs by retrofitting ballasts • Examples of common retrofits

4. 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 Input Current = 1 amp • 120 Watts of lighting @ 120V with PF=.60 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

5. 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 The distorted line represents a current wave shape with 17% THD versus a pure sinusoid wave shape with no THD

6. 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

7. THD: Typical Values • Electro Magnetic Ballasts: Less than 30% • ANSI Commercial Ballast Requirement: Less than 32% • Universal’s HP Family: Less than 10% • Typical screw-in CFL’s: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%.

8. 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.

9. 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.

10. 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

11. 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

12. 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 measurement standard for manufacturers is called 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.  

13. 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

14. 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

15. 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

16. 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)

17. Retrofit Example (Continued) Maximize energy savings by not over lighting

18. 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. | 18

19. Blue Line Blue BALLAST Red Yellow Yellow Red Blue Line BALLAST Blue Red Yellows Reds Yellows Blues Rapid Start to Instant Start Wiring – 2 Lamp 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 Electronic T8 Instant Start Wiring

20. Blue Line Red BALLAST Blue Yellow Yellow Red Yellows Reds Yellows Blues Yellows Reds Yellows Blues 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. Lamps from 2nd magnetic ballast Lamps from 1st magnetic ballast

21. 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 | 21

22. 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 Sound rated A, ideal for retail, schools, etc. Excellent Lumen Maintenance 90-95% Lumens at 40% rated life Light levels remain fairly consistent over time Excellent color 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 • Applications: • Warehouses • Gymnasiums • Big Box Retail • Industrial

23. 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

24. 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 | 24

25. HID to T5HO Lumen Comparisons 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 HID to T5HO Lumen Comparisons - Light Output over Time Delivered system lumens uses HID fixture efficiency of .80 & Fluorescent fixture of .92 Less Lumen depreciation allows for better designs for specific applications

26. 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

27. 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

28. 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 Delivered system lumens uses HID fixture efficiency of .80 & Fluorescent fixture of .92 6-Lamp T8 provides lower initial lumens but higher maintained lumens

29. 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

30. 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

31. 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.

32. 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

33. For Additional Information, please visit our website www.unvlt.com. Thank you Website: www.unvlt.com Nashville Customer Service: (800) 862-8666 Universal Technical Engineering Services: 1-800-BALLAST (1-800-225-5278)