CHAPTER 5. ENGINEERING ANALYSIS

TABLE OF CONTENTS

5.1 INTRODUCTION ........................................................................................................... 5­1

5.2 ENGINEERING ANALYSIS FRAMEWORK............................................................... 5­1

5.3 GENERAL SERVICE FLUORESCENT LAMPS.......................................................... 5­3

5.3.1 Four­Foot Medium Bipin..................................................................................... 5­6

5.3.1.1 Baseline Models....................................................................................... 5­6

5.3.1.2 Candidate Standard Levels ...................................................................... 5­8

5.3.1.3 System Power Rating............................................................................. 5­11

5.3.1.4 Results.................................................................................................... 5­19

5.3.2 Eight­foot Single Pin Slimline........................................................................... 5­24

5.3.2.1 Baseline Models..................................................................................... 5­24

5.3.2.2 Candidate Standard Levels .................................................................... 5­25

5.3.2.3 System Power Rating............................................................................. 5­28

5.3.2.4 Results.................................................................................................... 5­32

5.3.3 Eight­Foot Recessed Double Contact HO ......................................................... 5­36

5.3.3.1 Baseline Models..................................................................................... 5­36

5.3.3.2 Candidate Standard Levels .................................................................... 5­36

5.3.3.3 System Power Rating............................................................................. 5­39

5.3.3.4 Results.................................................................................................... 5­41

5.4 INCANDESCENT REFLECTOR LAMPS................................................................... 5­44

5.4.1 Baseline Models................................................................................................. 5­45

5.4.2 Candidate Standard Levels ................................................................................ 5­45

5.4.3 Results................................................................................................................ 5­47

5.5 SCALING TO PRODUCT CLASSES NOT ANALYZED .......................................... 5­49

5.5.1 General Service Fluorescent Lamps .................................................................. 5­49

5.5.2 Incandescent Reflector Lamps........................................................................... 5­50

REFERENCES .......................................................................................................................... 5­52

LIST OF TABLES

Table 5.3.1 DOE ANOPR Product Classes for General Service Fluorescent Lamps ................. 5­4

Table 5.3.2 Baseline Lamps for Four­Foot Medium Bipin Engineering Analysis..................... 5­8

Table 5.3.3 Summary of the CSLs for Four­Foot Medium Bipin Fluorescent Lamps............... 5­9

Table 5.3.4 4­Foot Medium Bipin Lamp Designs..................................................................... 5­11

Table 5.3.5 Lamp Replacement Engineering Analysis for a Three­Lamp 40W T12, 4,100K

System........................................................................................................................................ 5­20

Table 5.3.6 Lamp and Ballast Replacement Engineering Analysis for a Three­Lamp 40W T12,

4,100K System........................................................................................................................... 5­21

Table 5.3.7 Lamp and Ballast Replacement Engineering Analysis for a Three­Lamp 34W T12,

4,100K System........................................................................................................................... 5­22

5­i
Table 5.3.8 Lamp Replacement Engineering Analysis for a Three­Lamp 32W T8, 4,100K

System........................................................................................................................................ 5­23

Table 5.3.9 Lamp and Ballast Replacement Engineering Analysis for a Three­Lamp 32W T8,

4,100K System........................................................................................................................... 5­23

Table 5.3.10 Baseline Units of Analysis for Eight­Foot Linear Single Pin Slimline Lamps... 5­25

Table 5.3.11. Summary of the CSLs for Eight­Foot Single Pin Fluorescent Lamps................ 5­26

Table 5.3.12 8­Foot Single Pin Slimline Lamp Designs ........................................................... 5­28

Table 5.3.13 Lamp Replacement Engineering Analysis for a 75W T12, 4,100K System ....... 5­33

Table 5.3.14 Lamp­and­Ballast Replacement Engineering Analysis for a 75W T12, 4,100K

System........................................................................................................................................ 5­33

Table 5.3.15 Lamp­and­Ballast Replacement Engineering Analysis for a 60W T12, 4,100K

System........................................................................................................................................ 5­34

Table 5.3.16 Lamp Replacement Engineering Analysis for a Two­Lamp, 59W, T8, 4,100K

System........................................................................................................................................ 5­35

Table 5.3.17 Lamp­and­Ballast Replacement Engineering Analysis for a Two­Lamp, 59W, T8,

4,100K System........................................................................................................................... 5­35

Table 5.3.18 Baseline Units of Analysis for Eight­Foot Linear High­Output Lamps.............. 5­36

Table 5.3.19 Summary of the CSLs for Eight­Foot HO Fluorescent Lamps ........................... 5­37

Table 5.3.20 8­Foot Recessed Double Contact High Output Lamp Designs ............................ 5­39

Table 5.3.21 Lamp Replacement Engineering Analysis for a 110W T12, 4,100K System ..... 5­42

Table 5.3.22 Lamp­and­Ballast Replacement Engineering Analysis for a 110W T12, 4,100K

System........................................................................................................................................ 5­42

Table 5.3.23 Lamp­and­Ballast Replacement Engineering Analysis for a 95W T12, 4,100K

System........................................................................................................................................ 5­43

Table 5.4.1 Product Classes for Incandescent Reflector Lamps............................................... 5­44

Table 5.4.2 IRL Representative Product Class and Baseline Lamps........................................ 5­45

Table 5.4.3 Summary of the CSLs for IRL............................................................................... 5­47

Table 5.4.4 IRL Engineering Analysis 50W PAR30................................................................ 5­48

Table 5.4.5. IRL Engineering Analysis for 75W PAR38 ......................................................... 5­49

Table 5.4.6 IRL Engineering Analysis for 90W PAR38 .......................................................... 5­49

LIST OF FIGURES

Figure 5.3.1 Four­Foot Medium Bipin Fluorescent Lamp Candidate Standard Levels ........... 5­10

Figure 5.3.2 Three­Lamp 32W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

0.98­1.02 .................................................................................................................................... 5­12

Figure 5.3.3 Three­Lamp 30W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

1.07­1.12 .................................................................................................................................... 5­12

Figure 5.3.4 Three­Lamp 28W T8 120V Ballasts with THD <10 Percent, PF >0.95, and BEF

1.22­1.24 .................................................................................................................................... 5­13

Figure 5.3.5 Three­Lamp 25W T8 120V Ballasts with THD <10 Percent, and BEF 1.26­1.33 .. 5­

Figure 5.3.6 Two­Lamp 32W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

1.48­1.52 .................................................................................................................................... 5­14

Figure 5.3.7 Two­Lamp 30W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

1.55­1.65 .................................................................................................................................... 5­15

5­ii

13
Figure 5.3.8 Two­Lamp 28W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

1.55­1.65 .................................................................................................................................... 5­15

Figure 5.3.9 Two­Lamp 25W T8 120V Ballasts with THD <10 Percent, PF >0.95, and BEF 2.0

.................................................................................................................................................... 5­16

Figure 5.3.10 Two­Lamp 40W 120V Ballasts with <20 Percent THD, PF >0.95, and BEF 1.20­

1.22............................................................................................................................................. 5­17

Figure 5.3.11 Three­Lamp 40W 120V Ballasts Linear Fit (Based on Slope Change from TwoLamp to Three­Lamp Ballasts for 32W T8 Applied to T12 and Common T12 Electronic Ballast)

.................................................................................................................................................... 5­18

Figure 5.3.12 Two­Lamp 34W 120V Ballasts with <20 Percent THD, PF >0.95, and BEF 1.42­

1.44............................................................................................................................................. 5­18

Figure 5.3.13 Three­Lamp 34W 120V Ballasts (Based on Slope Change from Two­Lamp to

Three­Lamp Ballasts for T8 Applied to T12 and Common T12 Electronic Ballast) ................ 5­19

Figure 5.3.14 Eight­Foot Single Pin Slimline Fluorescent Lamp Candidate Standard Levels. 5­27

Figure 5.3.15 Two­Lamp 75W T12 120V Ballasts with THD <20 percent, PF >0.95, and BEF

0.64­0.66; Linear Fit: m=100.0, b=47.0 .................................................................................... 5­29

Figure 5.3.16 Two­Lamp 60W T12 120V Ballasts with THD <20 percent, PF >0.95, and BEF

0.79­0.80; Linear Fit: m=100.0, b=22.0 .................................................................................... 5­29

Figure 5.3.17 Two­Lamp 59W T8 120V Ballasts with THD <20 percent, PF >0.95, and BEF

0.77­0.79; Linear Fit: m=123.4, b=4.3 ...................................................................................... 5­30

Figure 5.3.18 Two­Lamp 57W T8 120V Ballasts with THD <20 percent, PF >0.95, and BEF

0.80­0.81; Linear Fit: m=50.0, b=63.5 ...................................................................................... 5­31

Figure 5.3.19 Two­Lamp 55W T8 120V Ballasts with THD <10 percent, and BEF 0.86; Linear

Fit: m=118.4, b=­2.2 .................................................................................................................. 5­31

Figure 5.3.20 Eight­Foot HO Fluorescent Lamp Candidate Standard Levels.......................... 5­38

Figure 5.3.21 Two­Lamp 110W T12 120V Ballasts with THD <20 percent, PF >0.95, and BEF

0.42­0.43; Linear Fit: m=307.7, b=­65.4 ................................................................................... 5­40

Figure 5.3.22 Two­Lamp 95W T12 120V Ballasts with THD <20 percent, PF >0.95, and BEF

0.48­0.52; Linear Fit: m=433.3, b=­204.3 ................................................................................. 5­40

Figure 5.3.23 Two­Lamp 86W T8 120V Ballasts with THD <20 percent, PF >0.95, and BEF

0.54­0.55; Linear Fit: m=128.6, b=46.9 .................................................................................... 5­41

Figure 5.4.1 IRL Baselines and Reduced Wattage Options...................................................... 5­47

5­iii
CHAPTER 5. ENGINEERING ANALYSIS

5.1 INTRODUCTION

This chapter provides the technical support documentation for the engineering analyses

of general service fluorescent lamps (GSFL) and incandescent reflector lamps (IRL). Generally,

the purpose of the engineering analysis is to estimate the relationship between cost and efficiency

for a range of products, spanning from the typical baseline product to the maximum

technologically feasible product; develop candidate standard levels (CSLs) that encompass this

range; and develop power rating estimates for the products analyzed. The outputs from the

engineering analysis are critical inputs to subsequent cost­benefit calculations for individual

consumers.

The engineering analysis follows the screening analysis (Chapter 4), in which the U.S.

Department of Energy (DOE) identifies design options that are later used for the rulemaking

analyses. Design options include discrete technologies, such as krypton fill gas, that incorporate

one or more technologies that improve efficacy. DOE develops product efficacy levels

associated with lamps designs that incorporate a range of design options.

While some engineering analyses for other rulemakings discuss manufacturer production

costs or selling prices and relate cost or price to efficiency, this engineering analysis does not

address manufacturer costs or mark­ups. In this rulemaking, DOE develops end­user prices for

lamp and lamp­and­ballast designs analyzed by discounting published list prices (i.e., “blue book

pricing”). The product price determination (Chapter 7) discusses the pricing methodology and

results. By combining the results of the engineering analysis and the product price

determination, DOE derives the necessary inputs for use in the life cycle cost (LCC) analysis and

national impacts analysis (NIA). In particular, DOE develops lamp and lamp­and­ballast designs

associated with particular CSLs and end­user prices.

This chapter starts with an outline of the engineering analysis (section 5.2), followed by

specifics on the engineering analysis for GSFL (section 5.3) and IRL (section 5.3). Each section

provides detailed information on the baseline lamps and representative product classes DOE

chooses to analyze, the development of CSLs, and the results of the engineering analysis.

Section 5.5 discusses how DOE extends its results from the representative product classes to

those products it does not analyze.

5.2 ENGINEERING ANALYSIS FRAMEWORK

To the extent possible, DOE bases the engineering analysis on commercially available

lamps that incorporate the design options identified in the technology assessment and screening

analysis (Chapter 4). For GSFL, all lamp­and­ballast designs are commercially available and

have publicly available performance and price information. DOE also bases the majority of the

engineering analysis for IRL on commercially available lamps. However, where needed, DOE

5­1
supplements these lamps with additional model lamps that use commercially available

technologies.

The engineering analysis for each of the two categories of lamps DOE analyzes in this

rulemaking (i.e., GSFL and IRL) follows a similar approach:

Step 1. Representative Product Classes. DOE reviews covered lamps and the associated

product classes. When a product has multiple product classes, DOE selects certain

classes as “representative” and concentrates its analytical effort on these. DOE

selects representative product classes primarily because of their high market

volumes. Section 5.5 discusses how DOE extrapolated from representative product

classes to other product classes.

Step 2. Baseline Lamps. DOE selects baseline lamps from the representative product

classes. Generally, a baseline lamp is one that just meets existing mandatory energy

conservation standards or represents the typical lamp sold. DOE selects specific

characteristics such as certain correlated color temperatures (CCTs), operating

lifetimes, and light outputs to characterize the most common lamps consumers

purchase. DOE selects multiple baseline lamps in each product class to ensure

consideration of different high­volume lamps and their associated consumer

economics.

Step 3. Candidate Lamps and Ballast Designs. DOE selects more efficacious lamps for

each baseline lamp in the representative product classes. DOE considers

technologies not eliminated in the screening analysis. DOE considers these

technologies either explicitly as design options or implicitly as design options

incorporated into commercially available lamps at the efficiency levels evaluated.

In identifying more efficacious lamp and ballast designs, DOE recognizes that a

lamp’s lumen package and performance characteristics are important design criteria

for consumers. For example, if consumers do not have the option to purchase

substitution lamps or lamp­and­ballast systems with similar lumen packages under

an energy conservation standard, consumers would need to change the lighting

design to maintain a similar light output. Therefore, DOE establishes lamp­andballast designs for the LCC analysis so that potential light output is equal to, greater

than, or no more than 10 percent less than the light output of the baseline system.

DOE also chooses substitute lamps with performance characteristics similar to

those of the baseline lamps.

In identifying more efficacious substitutes, DOE uses a database of commercially

available lamps. For the GSFL LCC, DOE develops the engineering analysis based

on two substitution scenarios in which consumers can maintain light output while

decreasing energy consumption. In the first scenario, the consumer replaces the

baseline lamp with a more efficacious, lower­wattage lamp that operates on the

existing ballast. In the second scenario, the consumer replaces the lamp­and­ballast

system with a more efficacious same or lower­wattage lamp and a different ballast.

For example, a lamp­and­ballast system with a more efficacious, same­wattage

5­2
lamp and lower ballast factor

a (BF) ballast will consume less energy and maintain

light output.

For IRL, DOE uses some commercially available lamps, but also developed

“model” lamps. These models incorporate designs that may not be commercially

available for certain lamp types and wattages, but use commercially available

technologies.

Step 4. Candidate Standard Levels. After identifying the more efficacious substitutes for

each baseline lamp or lamp­and­ballast system, DOE develops CSLs based on three

factors: (1) the design options associated with the specific lamps being studied (e.g.,

grades of phosphor for fluorescent lamps, the use of halogen capsules for IRL, etc.);

(2) the ability of lamps across wattages to comply with the CSL of a given product

b class; and (3) the maximum technologically feasible efficacy level.

The sections that follow discuss how DOE applies this methodology to each product class

to create the engineering analysis.

5.3 GENERAL SERVICE FLUORESCENT LAMPS

As discussed in the market and technology assessment (Chapter 3), DOE revises the

Energy Policy and Conservation Act (EPCA) table of standards for fluorescent lamps to eight

product classes, as shown in Table 5.3.1. Of these eight product classes, DOE is choosing to

analyze the three that represent the three highest shipment volumes–4­foot medium bipin, 8­foot

single pin slimline, and 8­foot recessed double contact high output (HO)–all with a CCT less

than or equal to 4,500 Kelvin (K). The 4­foot medium bipin lamps constitute the vast majority

of GSFL sales. These are followed, in order of unit sales, by 8­foot single pin slimline lamps

and 8­foot recessed double contact HO lamps, which together constitute less than a quarter of

GSFL sales. Shipments of 2­foot U­shaped lamps account for less than five percent of GSFL

1

unit sales historically. Given the relatively small market share of U­shaped lamps, DOE does

not explicitly analyze these lamps. Lamps with CCT greater than 4,500K represent a small

market share of GSFL. Therefore, DOE is choosing to analyze lamps with CCT less than or

equal to 4,500K. DOE discusses each of the three representative product classes separately in

the sections that follow.

Although DOE is not analyzing the 2­foot U­shaped lamps or lamps that have a CCT

greater than 4,500K, DOE will establish standards for these product classes. DOE will extend its

decision for the 4­foot medium bipin product class to the 2­foot U­shaped product class. This is

a The “ballast factor” of a ballast is the ratio of the light output of a fluorescent lamp or lamps operated on a ballast

to the light output of the lamp(s) operated on a standard (reference) ballast. Ballast factor depends on both the

ballast and the lamp type; a single ballast can have several ballast factors depending on lamp type. The light output

of a single fluorescent lamp is measured on a ballast with a ballast factor of 1.0. One can reduce the light output of a

lamp­and­ballast system by operating a lamp on a ballast with a lower ballast factor. b Efficacy levels span multiple lamps of different wattages. In selecting CSLs, DOE considered whether lamps of

different wattages can meet the efficacy levels prescribed by those CSLs.

5­3
possible because 2­foot U­shaped lamps generally are operated in the same way and generally

span the same wattages as 4­foot medium bipin lamps. For lamps whose CCT is greater than

4,500K, DOE will extend standards for similar lamp types with a CCT of less than or equal to

4,500K. This is also possible because lamps with a CCT of less than or equal to 4,500K operate

in the same way and generally span the same wattages as those with a CCT greater than 4,500K.

Section 5.5 provides more information on extending standards to those product classes that DOE

does not analyze.

Table 5.3.1 DOE ANOPR Product Classes for General Service Fluorescent Lamps

Lamp Type

For CCT ≤ 4,500K

Minimum Lamp Efficacy

lm/W*

For CCT > 4,500K

Minimum Lamp

Efficacy

lm/W

4­foot medium bipin Representative product class Scaled from ≤4,500K

2­foot U­shaped Scaled from 4­foot medium bipin Scaled from ≤4,500K

8­foot single pin slimline Representative product class Scaled from ≤4,500K

8­foot recessed double contact HO Representative product class Scaled from ≤4,500K

* lm/W = lumens per watt

In the engineering analysis for GSFL, DOE bases its CSLs on lamps. This is because the

energy conservation standards only apply to lamps. However, DOE uses a systems approach in

analyzing these representative product classes because both lamps and ballasts determine a

system’s energy use and light output. DOE pairs a lamp with a ballast to develop lamp­andballast systems. By using a systems approach, DOE can demonstrate the actual energy

consumption and light output of an operating lamp.

Using this systems approach, DOE can select a variety of energy­saving lamp­and­ballast

systems per CSL. In general, DOE chooses its lamp designs (which refer to lamp substitution

options) and lamp­and­ballast designs (which refer to lamp­and­ballast substitution options) by

selecting commercially available fluorescent lamps at higher efficacies than the baseline lamps.

Higher efficacies are achieved through a variety of technologies. As discussed in the screening

analysis (Chapter 4), DOE considers commercially available GSFL that use highly emissive

electrode coatings, higher efficiency lamp fill gas composition, higher efficiency phosphors,

glass coatings, or higher efficiency lamp diameter to achieve higher efficacy lamp designs.

For the LCC, DOE analyzes lamp­and­ballast systems that both save energy and maintain

comparable light output. In particular, DOE considers lamp­and­ballast designs that emit mean

lumens equal to, greater than, or no more than 10 percent less than the light output of the

baseline system. DOE maintains light output across efficacy levels to ensure that products

supply equivalent service in the base case and standards case.

In assessing light output, DOE makes a distinction between mean and initial lumens.

DOE uses initial lumens in its test procedures to measure compliance with a standard. This is

consistent with consensus industry standards on efficacy measurements. Therefore, DOE uses

initial lumens to calculate CSLs. However, the light output of a lamp decreases over time. To

5­4
account for this real­world depreciation in lumens, DOE uses mean lumens in determining

equivalent substitutes in the LCC and in determining the light output of GSFL in the NIA.

For GSFL, energy savings can be achieved either through lamp replacements or lampand­ballast replacements. For lamp replacements, DOE analyzes reduced­wattage, higherefficacy lamps for use on the existing ballast. For lamp­and­ballast replacements, DOE uses a

variety of lamp­and­ballast combinations to obtain energy savings and maintain comparable

mean lumens. These combinations include both reduced­wattage lamps and constant­wattage

lamps. For example, one can achieve energy savings while maintaining mean lumen output by

using a similar­wattage, higher­efficacy lamp with a lower BF ballast.

Some consumers may operate non­energy saving systems. For example, a consumer who

pairs a constant­wattage, higher­efficacy lamp with an existing ballast will get more light output

but will not save energy. DOE does not consider such non­energy­saving systems in the LCC

because energy savings determine whether a consumer can recoup any higher first costs of

replacement products. However, DOE does take into account the use of both energy­saving and

non­energy­saving systems when aggregating market behavior in the NIA. Therefore, DOE

considers lamp­and­ballast systems that do not save energy and may over­ or under­light. This

reflects the fact that DOE cannot require consumers to change their ballast along with their lamp.

Appendix 5A shows lamp­and­ballast designs considered in the NIA.

Because DOE is using a systems approach, the system power rating is an important result

of the engineering analysis. The system power rating represents the energy consumption rate of

both the lamps and ballast, and therefore is actually greater than simply the rated lamp power.

While the rated lamp power affects the system power, the system power is also affected by the

type of ballast used, the BF of that ballast, and the number of lamps operated per ballast.

DOE calculates the system power data using published catalog information. For each

lamp wattage and ballast type, DOE linearly fits the system power rating of a lamp on several

different ballasts with varying ballast factors. DOE uses this linear fit to derive the system

power rating of the lamp on the ballasts used in the analysis. The linear fit follows the equation

below:

SPR = m * BF + b Eq. 5.1

where:

SPR = System Power Rating

BF = Ballast Factor

m = Slope of Linear Fit

b = Y­Intercept of Linear Fit

DOE considers both magnetic and electronic ballasts. For 4­foot T8 and 4­foot T12

systems, DOE uses system power data from manufacturer literature to develop a linear fit for

lamps on a three­lamp, 120V, electronic instant­start ballast with similar ballast efficacy factors

5­5
(BEF).

c For some 4­foot T12s, DOE also uses a one­lamp and a two­lamp 120V, magnetic,

rapid­start ballast with a common ballast efficacy factor. A linear fit was not necessary for these

magnetic systems because DOE uses only one type of magnetic ballast in the analysis. For 8­

foot T8s and 8­foot T12s, DOE uses system power data from manufacturer literature to develop a

linear fit for lamps on a two­lamp, 120V, electronic instant­start ballast. DOE also uses data for

some baseline 8­foot T12 slimline lamps on two­lamp, 120V, magnetic, instant­start ballasts.

Again, a linear fit is not necessary for the magnetic systems because DOE uses only one ballast

in the analysis.

5.3.1 Four­Foot Medium Bipin

DOE is selecting the 4­foot medium bipin product class as one of the representative

product classes for GSFL because it has the highest volume shipments of all the product classes

for fluorescent lamps. DOE must pair each lamp it analyzes with a ballast. DOE reviews the

range of new lamp­and­ballast combinations and found that ballasts for 4­foot medium bipin

ballasts are available in a variety of lamp­per­ballast designs. For example, electronic ballasts

are typically manufactured in one­, two­, three­, and four­lamp versions. According to the 2000

2

rule on GSFL ballasts (“2000 Ballast Rule”), there are on average 2.8 lamps per 4­foot medium

3 bipin system. 62 FR 56740 (September 19, 2000). To accurately represent the market yet

simplify the analysis, DOE uses a three­lamp system for 4­foot medium bipin lamps operating on

electronic ballasts. (This decision effectively spreads the cost of a new ballast over the average

number of lamps per system). To make a comparison between electronic and magnetic 4­foot

medium bipin systems, and because three­lamp magnetic ballasts are typically not sold, DOE

develops a system that combines a two­lamp magnetic and one­lamp magnetic ballast. This

allows DOE to compare similar light output packages and make a level comparison on energy

d

use.

5.3.1.1 Baseline Models

This product class represents both T12 and T8 4­foot medium bipin lamps, which operate

on different ballasts and are both high­volume lamps. To reflect the most common lamp and

wattage combinations for this product class, DOE is selecting three baseline lamp/wattage

combinations for the 4­foot medium bipin product class: a 32W T8, a 34W T12, and a 40W T12.

c Energy efficient ballasts are characterized as having higher ballast efficacy factors (BEF). The BEF is directly

related to the quotient of the BF and the power consumed by the ballast, such that a ballast maintaining BF while

reducing power consumption will have a higher BEF, and be a more energy­efficient ballast. In its ANOPR

analysis, DOE varied the ballast BF, not the BEF (given the same lamp wattage and ballast type (“electronic” or

“magnetic”)), in its assessment of standards for fluorescent lamps. DOE will be considering new and amended BEF

standards in a separate fluorescent lamp ballast rulemaking. d DOE recognizes that the combined cost of a one­lamp and two­lamp magnetic system would be higher than the

cost of a three­lamp system if it were manufactured. However, the comparative economics between a one­lamp and

two­lamp magnetic ballast versus a three­lamp electronic ballast is not an issue in DOE’s calculation of the LCC.

Since ballast standards will be effective in 2010, DOE assumes all new ballast sales are electronic. As a result, the

only magnetic ballasts DOE models are pre­existing magnetic ballasts in the base case. Because they were

purchased before the standards rule, DOE assumes that the magnetic ballast is a sunk cost. Therefore, the only costs

considered in the LCC are electronic ballasts, for which DOE uses three­lamp systems.

5­6
In 2005, T8 lamps represented 57 percent of the 4­foot medium bipin shipments, of which the

32W lamp was the most common. The 2005 shipments of 4­foot T12 lamps represented 43

percent of all 4­foot medium bipin shipments. The 34W T12 lamp was approximately two­thirds

of these shipments and the 40W T12 was approximately one­third. Therefore, these three

baseline lamps represent the three highest volume lamp diameter and wattage combinations for

the 4­foot medium bipin product class.

For each of these three baseline model lamps, DOE has developed a set of typical

performance characteristics. For the 32W T8 lamp, DOE is selecting a lamp using a 700 series

rare earth phosphor. These lamps typically have a color rendering index (CRI) of 70 to 79. DOE

found in discussion with industry experts that this lamp represents the majority of 4­foot T8

lamps sold. Typically, a baseline product is a unit that just meets the existing energy

conservation standard for that product (which for this product class is 75.0 lm/W). However,

there are no T8 lamps in this product class with an efficacy as low as 75.0 lm/W. Therefore,

DOE is selecting a T8 lamp that represents the most common one sold, approximately 86.2

lm/W. For new system installations, DOE is selecting T8 lamps operating in three­lamp fixtures.

These fixtures are assumed to operate on a 120V instant­start electronic ballast with a 0.88 BF.

Together, the lamp­and­ballast combination in this three­lamp system has a light emission of

approximately 6,650 mean lumens (and 7,390 initial lumens) when operating with the baseline

lamp.

For the 34W T12 lamp, DOE is selecting a cool white lamp with an efficacy that is

slightly above the minimum efficiency standard (77.9 lm/W). A review of the product catalogs

finds that there are no 34W T12 lamps that are just compliant with the standard (75.0 lm/W), or

any between 75.0 and 77.9 lm/W which are otherwise covered products. For the 40W T12 lamp,

DOE is selecting a lamp using 700 series rare earth phosphor and an efficacy of 80 lm/W. A

review of the product catalogs finds that 40W T12 lamps below this efficacy are low­volume

product, since they fail to meet the Energy Policy Act of 1992 (EPACT 1992) requirement for

CRI and are labeled for residential use only. DOE pairs both T12 lamps, with a rapid­start 120V

magnetic ballast, which exhibits a 0.88 BF when operating the 34W lamp and a 0.95 BF when

operating the 40W lamp. This combination of lamp and ballast represents the most common

configuration for this lamp in existing and new installations. Together, this lamp­and­ballast

combination in a three­lamp fixture creates a system package of over 6,070 mean lumens (and

nearly 7,000 initial lumens) for the baseline 34W lamps and approximately 8,210 mean lumens

(and 9,120 initial lumens) for the baseline 40W lamps. As mentioned earlier, DOE assumes the

three­lamp fixture is wired using two magnetic ballasts – a one­lamp and a two­lamp ballast

connected in tandem with an adjacent fixture.

For all three baseline lamps and the more efficacious lamp designs, DOE analyzes

fluorescent lamps with a CCT of 4,100K. DOE is selecting this CCT because it represents the

highest volume CCT for this category of lamps and because it is falls within the CCT span of the

analyzed product class (2,500K to 4,500K). Additionally, the typical lifetime for all three

baseline models in this product class is 20,000 hours (using a 3­hour on­off testing cycle). While

there are lamps in this product class that have other lifetimes under the 3 hour on­off testing

cycle, such as 18,000 or 24,000 hrs, these lamps do not represent the typical unit sold for these

three lamp types.

5­7
Table 5.3.2 Baseline Lamps for Four­Foot Medium Bipin Engineering Analysis

Lamp

Diameter

Nominal

Wattage

CRI CCT Rated

Efficacy*

Initial

Light

Output

Mean

Light

Output

Life

W K lm/W lm lm hr

T12 40 72 4,100 80.0 3,200 2,880 20,000

T12 34 62 4,100 77.9 2,650 2,300 20,000

T8 32 75 4,100 86.2 2,800 2,520 20,000

* Rated efficacy is based on the rated wattage of the lamps, which for T12 lamps is 40W and 34W and for the 32W

T8 lamp is 32.5W.

5.3.1.2 Candidate Standard Levels

In this product class, DOE is establishing CSLs around designs options that are consistent

across all three baseline lamps. However, because these lamps have different efficacy values and

some represent various design options, some CSLs affect only one or two baseline lamps.

However, the full range of CSLs ultimately specifies requirements that are at some point above

the efficacy values of all the baseline lamps sold, and therefore affect all three baseline lamps.

In selecting CSLs, DOE considers two different paths to energy savings. The first

concentrates on reduced­wattage replacement lamps that could be installed in a socket and

operate on the existing ballast. These lower­wattage replacement lamps have a higher efficacy

and therefore produce approximately the same light output as the baseline lamp (i.e., light output

never drops below 10 percent of the baseline system).

The other path to energy savings involves lamps that have the same or less wattage as the

baseline lamp, but operate on a new ballast with a different BF so the system power rating is

lower. DOE is selecting a ballast with a particular BF in conjunction with the more efficacious

lamp to produce approximately the same light output as the baseline lamp (i.e., light output never

drops below 10 percent of the baseline system).

Table 5.3.3 summarizes the CSLs considered for 4­foot medium bipin lamps. The

following discussion identifies the steps and technologies associated with each CSL DOE

considered. As discussed in the screening analysis (Chapter 4), DOE uses design options that

achieve a higher efficacy with highly emissive electrode coatings, higher­efficiency lamp fill gas

composition, higher­efficiency phosphors, glass coatings, or higher­efficiency lamp diameter.

Because high­efficiency phosphors and lamp diameter are common methods to achieve higher

efficacies, DOE has identified the diameter and phosphor associated with each CSL:

CSL1, 82.4 lm/W. This level affects the two T12 baseline lamps. Because the baseline

T8 lamp is above this efficacy level, consumers using the T8 lamp are not affected. The 34W

T12 moves from a cool white halophosphor to a 700 series rare earth phosphor. The 40W T12

lamp moves from the 700 series rare earth to either an improved 700 series rare earth phosphor

or 800 series lamp.

5­8
CSL2, 85.0 lm/W. This level also only affects T12 lamps. For the 34W T12, the lamps

change from 700 series to 800 series rare earth phosphor. The 40W T12 lamp at this level uses

800 series rare earth phosphor.

CSL3, 90.0 lm/W. This level affects all three baseline lamps. The 32W T8 lamp that

used 700 series rare earth phosphor in the baseline migrates to an 800 series rare earth in a 32W

lamp. The T12 lamp uses an 800 series rare earth phosphor, and may incorporate other design

options to enhance efficacy, such as a different gas fill or increased thickness of the bulb­wall

phosphor.

CSL4, 92.3 lm/W. This level affects all three baseline lamps. However, no T12 lamps

are commercially available that meet this efficacy requirement. Therefore, users of T12 lamps

would be forced to replace their ballasts and operate T8 lamps instead. For the T8 lamps, this

level requires the use of a higher­efficacy 800 series rare earth phosphor. A 30W T8 lamp that

produces an equivalent amount of light as the baseline unit on a similar ballast meets this CSL.

CSL5, 95.4 lm/W. This level affects all three baseline lamps. However, no T12 lamps

that can meet this efficacy requirement are commercially available. Therefore, users of T12

lamps would be forced to replace their ballasts and operate T8 lamps instead. For the T8 lamps,

this level represents “max­tech,” the highest efficacy level available today. It uses 800 series rare

earth phosphor and may incorporate other efficacy improvements, such as a different gas fill or

increased thickness of the bulb­wall phosphor. Both 28W and 25W T8 lamps that produce an

equivalent amount of light on the same ballast as the baseline unit meet this CSL.

Table 5.3.3 Summary of the CSLs for Four­Foot Medium Bipin Fluorescent Lamps

Candidate Standard Level Efficacy Requirement

lm/W

CSL1 82.4

CSL2 85.0

CSL3 90.0

CSL4 92.3

CSL5 95.4

Figure 5.3.1 illustrates the five CSLs on a plot of fluorescent lamps DOE is selecting to

analyze. A line at 75 lm/W denotes the existing energy conservation standard (from EPACT

1992). Square boxes and labels identify the three baseline lamps. The plot shows replacement

lamps DOE considers for each lamp at higher efficacies. Some lamps are at the same wattage,

but have a higher efficacy; others have a combination of lower wattage and higher efficacy so

that the lamp­and­ballast system produces light output no less than 10 percent of the baseline.

5­9
CSL1

CSL2

CSL3

CSL4

CSL5

EPACT 1992

72.0

74.0

76.0

78.0

80.0

82.0

84.0

86.0

88.0

90.0

92.0

94.0

96.0

98.0

100.0

R

ate

d

L

a

m

p

Effic

a

c

y (lm/W)

4­foot T8 medium bipin 4­foot T12 medium bipin

40W T12 Baseline

34W T12 Baseline

32W T8 Baseline

24 26 28 30 32 34 36 38 40 42

Rated Wattage (W)

Figure 5.3.1 Four­Foot Medium Bipin Fluorescent Lamp Candidate Standard Levels

Table 5.3.4 provides detailed information on the 4­foot medium bipin lamp designs used

in the engineering analysis and subsequent analyses.

5­10
Table 5.3.4 4­Foot Medium Bipin Lamp Designs

CSL

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial Light

Output

Mean Light

Output Life CRI

W W lm/W lm lm hr

Baseline/0 T12 40 40.0 80.0 3,200 2,880 20,000 70

Baseline/0 T12 34 34.0 77.9 2,650 2,300 20,000 62

1 T12 34 34.0 82.4 2,800 2,460 20,000 70

1 T12 40 40.0 82.5 3,300 3,000 20,000 80

2 T12 40 40.0 85.0 3,400 3,060 24,000 80

2 T12 34 34.0 85.3 2,900 2,610 20,000 80

Baseline/2 T8 32 32.5 86.2 2,800 2,520 20,000 75

3 T12 40 40.0 90.0 3,600 3,250 24,000 85

3 T8 32 32.5 90.8 2,950 2,710 20,000 82

3 T12 34 34.0 91.2 3,100 2,790 24,000 85

4 T8 32 32.5 92.3 3,000 2,850 24,000 85

4 T8 30 30.0 95.0 2,850 2,680 18,000 82

5 T8 32 32.5 95.4 3,100 2,915 24,000 82

5 T8 28 28.0 97.3 2,725 2,560 18,000 82

5 T8 25 25.0 96.0 2,400 2,280 24,000 85

Section 5.3.1.4 provides detailed information on the lamp­and­ballast systems DOE uses

in the engineering analysis.

5.3.1.3 System Power Rating

As discussed in section 5.3, the system power rating is an important result of the

engineering analysis. DOE calculates the system power rating, which represents the energy

consumption rate of both the lamps and ballast, using published catalog information. For each

lamp wattage and ballast type, DOE applies a linear fit to several points identifying the system

power rating of a lamp on a ballast and the ballast factor of the ballast. The fit follows the form

of Eq. 5.1 where SPR = m * BF + b. DOE uses a linear form because the relationship is

approximately linear over the range of BFs and wattages considered.

The ballasts DOE uses typically have a total harmonic distortion (THD) less than 20

percent, power factors (PF) greater than 0.95, and typical ballast efficacy factors (BEF). Because

ballast efficiencies naturally increase as lamp wattages decrease, there is a natural progression to

higher typical BEFs at lower wattages. Also, because there is less manufacturer literature on

system power ratings of ballasts with lower wattage lamps, DOE uses fewer points to develop a

linear fit for the energy­saving lamp wattages. Figure 5.3.2 to Figure 5.3.5 show the linear fit

and ballast characteristics DOE uses to derive the system power rating for 3­lamp, 4­foot T8

lamps on electronic ballasts.

5­11
60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

105.0

110.0

S

y

ste

m

P

o

wer R

atin

g (W)

Linear Fit: m=89.8, b=8.5

0.70 0.75 0.80 0.85 0.90 0.95 1.00

Ballast Factor

Figure 5.3.2 Three­Lamp 32W T8 120V Ballasts with THD <20 Percent, PF >0.95, and

BEF 0.98­1.02

120.0

S

y

ste

m

P

o

w

er R

atin

g (W)

60.0

70.0

80.0

90.0

100.0

110.0

0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40

Ballast Factor

Linear Fit: m=80.8, b=9.4

Figure 5.3.3 Three­Lamp 30W T8 120V Ballasts with THD <20 Percent, PF >0.95, and

BEF 1.07­1.12

5­12
55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

105.0

S

y

ste

m

P

o

w

er R

atin

g (W)

Linear Fit: m=78.4, b=2.1

0.60 0.80 1.00 1.20 1.40

Ballast Factor

Figure 5.3.4 Three­Lamp 28W T8 120V Ballasts with THD <10 Percent, PF >0.95, and

BEF 1.22­1.24

50.0

55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

S

y

ste

m

P

o

w

er R

atin

g (W)

Linear Fit: m=87.3, b=9.9

0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40

Ballast Factor

Figure 5.3.5 Three­Lamp 25W T8 120V Ballasts with THD <10 Percent, and BEF 1.26­

5­13

1.33
Figure 5.3.6 to Figure 5.3.9 show the linear fit and ballast characteristics DOE uses to

derive the system power rating for two­lamp, 4­foot T8 lamps on electronic ballasts. DOE uses

the system power rating for these ballasts to derive both the system power rating for 4­foot T12

electronic ballasts and systems DOE uses in the NIA. The ballasts DOE uses typically have a

THD less than 20 percent, PFs greater than 0.95, and typical BEFs. Because ballast efficiencies

naturally increase as lamp wattages decrease, there is a natural progression to higher typical

BEFs at lower wattages. Also, because there is less manufacturer literature on system power

ratings of ballasts with lower wattage lamps, DOE uses fewer points to develop a linear fit for

the energy­saving lamp wattages.

S

y

ste

m

P

o

w

er R

atin

g (W) 85.0

80.0

75.0

70.0

65.0

60.0

55.0

50.0

45.0

40.0

Linear Fit: m=66.1, b=0.3

0.70 0.80 0.90 1.00 1.10 1.20

Ballast Factor

Figure 5.3.6 Two­Lamp 32W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

1.48­1.52

5­14
40.0

45.0

50.0

55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

S

y

ste

m

P

o

w

er R

atin

g (W)

Linear Fit: m=56.0, b=5.4

0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40

Ballast Factor

Figure 5.3.7 Two­Lamp 30W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

1.55­1.65

70.0

S

y

ste

m

P

o

w

er R

atin

g (W) 35.0

40.0

45.0

50.0

55.0

60.0

65.0

0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40

Ballast Factor

Linear Fit: m=52.3, b=1.7

Figure 5.3.8 Two­Lamp 28W T8 120V Ballasts with THD <20 Percent, PF >0.95, and BEF

1.55­1.65

5­15
2.0

30.0

35.0

40.0

45.0

50.0

55.0

60.0

65.0

70.0

75.0

80.0

S

y

ste

m

P

o

w

er R

atin

g (W)

Linear Fit: m=50.5, b=0.5

0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30

Ballast Factor

Figure 5.3.9 Two­Lamp 25W T8 120V Ballasts with THD <10 Percent, PF >0.95, and BEF

Figure 5.3.10 to Figure 5.3.13 show the linear fit and ballast characteristics DOE uses to

derive the system power rating for three­lamp, 4­foot T12 lamps on electronic ballasts. Because

manufacturer literature for these lamps is uncommon, DOE extrapolates linear fits from the twolamp, 4­foot T12 based on the relative difference between the three­lamp and two­lamp 32W T8

slopes. To develop the y­intercept, DOE uses a data point from manufacturer literature for threelamp, 4­foot T12s with a common BEF.

5­16
68.0

69.0

70.0

71.0

72.0

73.0

74.0

75.0

S

y

ste

m

P

o

w

er R

atin

g (W)

Linear Fit: m=50.5, b=28.5

0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94

Ballast Factor

Figure 5.3.10 Two­Lamp 40W 120V Ballasts with <20 Percent THD, PF >0.95, and BEF

1.20­1.22

5­17
S

y

ste

m

P

o

w

er R

atin

g (W) 120.0

115.0

110.0

105.0

100.0

95.0

90.0

Linear Fit: m=68.6, b=47.3

0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05

Ballast Factor

Figure 5.3.11 Three­Lamp 40W 120V Ballasts Linear Fit (Based on Slope Change from

Two­Lamp to Three­Lamp Ballasts for 32W T8 Applied to T12 and Common T12

Electronic Ballast)

68.0

S

y

ste

m

P

o

w

er R

atin

g (W)

66.0

64.0

62.0

60.0

58.0

56.0

54.0

Linear Fit: m=50.0, b=17.5

0.70 0.75 0.80 0.85 0.90 0.95 1.00

Ballast Factor

Figure 5.3.12 Two­Lamp 34W 120V Ballasts with <20 Percent THD, PF >0.95, and BEF

1.42­1.44

5­18
70.0

75.0

80.0

85.0

90.0

95.0

100.0

105.0

110.0

B

alla

st F

a

ctor

Linear Fit: m=68.6, b=31.3

0.75 0.80 0.85 0.90 0.95 1.00

ANSI Input Power (W)

Figure 5.3.13 Three­Lamp 34W 120V Ballasts (Based on Slope Change from Two­Lamp to

Three­Lamp Ballasts for T8 Applied to T12 and Common T12 Electronic Ballast)

5.3.1.4 Results

As discussed above, DOE is evaluating multiple baseline lamps for each product class to

provide a comprehensive understanding of the consumer economics. For each baseline lamp,

DOE considers only energy­saving options that result in approximately the same light output as

the baseline lamp system. Energy savings could either be achieved through lamp or lamp and

ballast replacements. Appendix 5A provides information on the additional lamp­and­ballast

designs DOE uses in the NIA.

Table 5.3.5 presents the engineering characteristics of lamp replacement options for a

baseline 40W T12, 4,100K lamp. Although a 34W T12 lamp is often considered a reduced

wattage replacement of the 40W T12 lamp, there are no lamp options that emit enough lumens to

fall within 10 percent of the baseline system lumens. The highest efficacy 34W T12 lamp

replacement is shown below in Table 5.3.5. The light output of this lamp­and­ballast design is

10.3 percent less than that of the baseline system. The same drop in lumen output is also

exhibited by the 34W T12 lamp on an electronic ballast of the same BF.

Table 5.3.6 presents the engineering characteristics of lamp and ballast replacement

options for a 40W T12, 4,100K lamp. Note that at the higher CSLs, DOE considers some T8

substitutes for the 40W T12 lamp. As discussed earlier, DOE adjusts the BF so that the

combination of lamp and ballast maintains light output so that potential light output is equal to,

greater than, or no more than 10 percent less than the light output of the baseline system. All

standards­case lamps for lamp and ballast replacements are placed on electronic T12s or ballasts

since ballast standards will be effective in 2010.

5­19
Table 5.3.5 Lamp Replacement Engineering Analysis for a Three­Lamp 40W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor*

System

Power

Rating

System

Initial

Light

Output

System

Mean Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 40 40 80 3,200 2,880 20,000 Magnetic 0.95 129.0 9,120 8,208

CSL3 T12 34 34 91.2 3,100 2,790 24,000 Magnetic 0.88 108.0 8,184 7,366

*Note: This difference in BFs does not represent a ballast replacement. Instead, the BF of magnetic ballasts changes when a different wattage lamp is installed.

5­20
Table 5.3.6 Lamp and Ballast Replacement Engineering Analysis for a Three­Lamp 40W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 40 40.0 80.0 3,200 2,880 20,000 Magnetic 0.95 129.0 9,120 8,208Baseline T12 40 40.0 80.0 3,200 2,880 20,000 Electronic 0.88 107.7 8,448 7,603

CSL1 T12 40 40.0 82.5 3,300 3,000 20,000 Electronic 0.88 107.7 8,712 7,920CSL1 T12 40 40.0 82.5 3,300 3,000 20,000 Electronic 0.87 107.0 8,613 7,830CSL2 T12 40 40.0 85.0 3,400 3,060 24,000 Electronic 0.87 107.0 8,874 7,987CSL2 T8 32 32.5 86.2 2,800 2,520 20,000 Electronic 1.18 114.5 9,912 8,921CSL3 T12 40 40.0 90.0 3,600 3,250 24,000 Electronic 0.87 107.0 9,396 8,483CSL3 T12 34 34.0 91.2 3,100 2,790 24,000 Electronic 0.88 91.7 8,184 7,366CSL3 T8 32 32.5 90.8 2,950 2,710 20,000 Electronic 1.00 98.3 8,850 8,130CSL4 T8 32 32.5 92.3 3,000 2,850 24,000 Electronic 0.88 87.5 7,920 7,524CSL4 T8 30 30.0 95.0 2,850 2,680 18,000 Electronic 1.00 90.2 8,550 8,040CSL5 T8 32 32.5 95.4 3,100 2,915 24,000 Electronic 0.88 87.5 8,184 7,696CSL5 T8 28 28.0 97.3 2,725 2,560 18,000 Electronic 1.00 80.5 8,175 7,680CSL5 T8 25 25.0 96.0 2,400 2,280 24,000 Electronic 1.18 93.0 8,496 8,071

Table 5.3.7 presents the engineering analysis results for the replacement lamp­and­ballast combinations for the 34W T12

baseline lamp. DOE has not identified any lower­wattage direct lamp replacement designs that could operate on the same ballast and

save energy. In this table, T8 lamp and ballast replacements are considered for the baseline lamp, and the BF is selected so that thenew system’s light output never drops below 10 percent of the baseline system.

5­21
Table 5.3.7 Lamp and Ballast Replacement Engineering Analysis for a Three­Lamp 34W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 34 34.0 77.9 2,650 2,300 20,000 Magnetic 0.88 108.0 6,996 6,072Baseline T12 34 34.0 77.9 2,650 2,300 20,000 Electronic 0.88 91.7 6,996 6,072

CSL1 T12 34 34.0 82.4 2,800 2,460 20,000 Electronic 0.88 91.7 7,392 6,494CSL1 T12 34 34.0 82.4 2,800 2,460 20,000 Electronic 0.86 90.3 7,224 6,347CSL2 T12 34 34.0 85.3 2,900 2,610 20,000 Electronic 0.86 90.3 7,482 6,734CSL2 T8 32 32.5 86.2 2,800 2,520 20,000 Electronic 0.88 87.5 7,392 6,653CSL3 T8 32 32.5 90.8 2,950 2,710 20,000 Electronic 0.78 78.5 6,903 6,341CSL3 T12 34 34.0 91.2 3,100 2,790 24,000 Electronic 0.86 90.3 7,998 7,198CSL4 T8 32 32.5 92.3 3,000 2,850 24,000 Electronic 0.75 75.9 6,750 6,413CSL4 T8 30 30.0 95.0 2,850 2,680 18,000 Electronic 0.78 72.4 6,669 6,271CSL5 T8 32 32.5 95.4 3,100 2,915 24,000 Electronic 0.75 75.9 6,975 6,559CSL5 T8 28 28.0 97.3 2,725 2,560 18,000 Electronic 0.78 63.3 6,377 5,990CSL5 T8 25 25.0 96.0 2,400 2,280 24,000 Electronic 0.88 66.8 6,336 6,019

Table 5.3.8 presents the engineering analysis results for the 32W T8 baseline lamp replacement. As shown below in Table

5.3.8, there are no lamp replacement options at CSL3 because the system lumens of reduced wattage lamp replacement options belowthis CSL are not maintained.

Table 5.3.9 presents the engineering analysis results for the replacement lamp and ballast combinations for the 32W T8

baseline lamp. For lamp­and­ballast replacement combinations, the BF is selected so that the new system’s light output is equal to,

greater than, or no more than 10 percent less than the light output of the baseline system. .

5­22
Table 5.3.8 Lamp Replacement Engineering Analysis for a Three­Lamp 32W T8, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline/

CSL2 T8 32 32.5 86.2 2,800 2,520 20,000 Electronic 0.88 87.5 7,392 6,653CSL4 T8 30 30.0 95.0 2,850 2,680 18,000 Electronic 0.88 80.5 7,524 7,075CSL5 T8 28 28.0 97.3 2,750 2,585 18,000 Electronic 0.88 71.1 7,260 6,824CSL5 T8 25 25.0 96.0 2,400 2,280 24,000 Electronic 0.88 66.8 6,336 6,019

Table 5.3.9 Lamp and Ballast Replacement Engineering Analysis for a Three­Lamp 32W T8, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline/

CSL2 T8 32 32.5 86.2 2,800 2,520 20,000 Electronic 0.88 87.5 7,392 6,653CSL3 T8 32 32.5 90.8 2,950 2,710 20,000 Electronic 0.78 78.5 6,903 6,341CSL4 T8 32 32.5 92.3 3,000 2,850 24,000 Electronic 0.75 75.9 6,750 6,413CSL4 T8 30 30.0 95.0 2,850 2,680 18,000 Electronic 0.78 72.4 6,669 6,271CSL5 T8 32 32.5 95.4 3,100 2,915 24,000 Electronic 0.75 75.9 6,975 6,559CSL5 T8 28 28.0 97.3 2,725 2,560 18,000 Electronic 0.88 71.1 7,194 6,758CSL5 T8 25 25.0 96.0 2,400 2,280 24,000 Electronic 0.88 66.8 6,336 6,019

5­23
5.3.2 Eight­foot Single Pin Slimline

5.3.2.1 Baseline Models

The 8­foot single pin slimline lamps are commonly manufactured in both T8 and T12

diameters. As discussed in Chapter 3, the T12 diameter represents approximately 85 percent of

all slimline lamp shipments. However, DOE projects that by 2011, T8s will account for 26

percent of all slimline lamp shipments. Therefore, DOE is selecting its baseline models for this

product class from both the T12 and T8 diameter. The two most popular wattages associated

with the T12 slimline lamp type are the 60W and 75W. For the 60W lamp, the cool white

halophosphor is the most popular. Therefore, DOE selected this as the baseline. The most

common 75W T12 lamp purchased uses a rare earth 700 series phosphor. For T8 lamps, the

most popular wattage is 59W. The most common lamp purchased at this wattage uses a rare

earth 700 series phosphor. As with the 4­foot medium bipin, DOE selects a CCT of 4,100K

because it is the most common CCT for this lamp type.

When selecting the lamp, DOE finds a small variance in the reported lumen output (and

therefore efficacy) of each lamp. DOE is selecting the least efficacious baseline lamps to ensure

that all the major manufacturers have a product available at the baseline.

DOE’s review of product literature for 8­foot T12 single pin slimline lamps indicates that

a 12,000­hour lifetime is typical, although this is shorter than the lifetime of the 4­foot medium

bipin. T12 lamps with a 15,000­hour lifetime for a 3­hour cycle are marketed as extended

performance products. Therefore, DOE is using a lifetime of 12,000 hours for a 3­hour cycle for

the baseline unit of analysis for T12 lamps.

DOE’s review of product literature for T8 lamps indicates that 15,000 hours is a typical

lifetime. T8 lamps with a 24,000­hour lifetime for a 3­hour cycle are marketed as extended

performance products. Therefore, DOE is using a lifetime of 15,000 hours for a 3­hour cycle for

the baseline unit of analysis for T8 lamps.

The most common ballast for T12 single pin lamps is a two­lamp, instant­start, 120V,

magnetic ballast. This ballast typically has a 0.94 BF when a 75W T12 single pin lamp is

installed and a 0.88 BF when a 60W T12 single pin lamp is installed. The most common ballast

used for T8 single pin lamps is a two­lamp, instant­start, 120V, electronic ballast with a 0.88 BF.

The 75W T12 baseline lamp­and­ballast combination creates a lumen package of approximately

11,100 mean lumens (and 12,070 initial lumens). The 60W T12 baseline lamp­and­ballast

combination creates a lumen package of approximately 8,210 mean lumens (and 9,330 initial

lumens). The 59W T8 baseline lamp­and­ballast combination creates a lumen package of almost

9,030 mean lumens (and more than 10,030 initial lumens).

5­24
Table 5.3.10 Baseline Units of Analysis for Eight­Foot Linear Single Pin Slimline Lamps

Lamp

Diameter

Nominal

Wattage

CRI CCT Rated

Efficacy*

Initial

Light

Output

Mean

Light

Output

Life

W K lm/W lm lm hr

T12 75 70 4,100 85.6 6,420 5,906 12,000

T12 60 62 4,100 87.6 5,300 4,664 12,000

T8 59 70 4,100 94.8 5,700 5,130 15,000

* Rated efficacy is based on the rated wattage of the lamps, which is 75W and 60.5W for T12 lamps and 60.1W for

T8 lamps.

5.3.2.2 Candidate Standard Levels

As with the previous product class, DOE is establishing CSLs for design options that are

consistent across the three baseline lamps. However, not every CSL affects every baseline lamp.

Because the three baseline lamps have different efficacy values, the first CSL only affects the

75W lamp. However, for CSL4 and above, the requirements affect all three baseline lamps.

In selecting CSLs, DOE considers two different paths to energy savings. One

concentrates on reduced wattage replacement lamps, which could be installed in a socket and

operate on the existing ballast. These lower­wattage replacement lamps have a higher efficacy

and therefore produce about the same light output as the baseline lamp (i.e., light output never

drops below 10 percent of the baseline system). The other path to energy savings involves lamps

that have the same or less wattage as the baseline lamp, but operate on a new ballast with a

different BF so the system energy is lower. DOE is selecting the BF with the more efficacious

lamp to produce approximately the same light output as the baseline lamp (i.e., light output never

drops below 10 percent of the baseline system).

The following discussion identifies the steps and technologies associated with each CSL

DOE considered. As discussed in the screening analysis (Chapter 4), DOE uses design options

with highly emissive electrode coatings, higher efficiency lamp fill gas composition, higher

efficiency phosphors, glass coatings, or higher efficiency lamp diameter to achieve a higher

efficacy level. Because high­efficiency phosphors and lamp diameter are common methods to

achieve higher efficacies, DOE has identified the diameter and phosphor associated with each

CSL:

CSL1, 87.3 lm/W. This level affects just the 75W T12 baseline lamp, moving this

technology from a 700 series rare earth phosphor to an 800 series rare earth phosphor. This level

does not affect the 60W T12 baseline lamp since it is below the baseline efficacy.

CSL2, 92.0 lm/W. This level represents the highest efficacy for the T12 lamp at 75W. At

that efficacy, the lamp is incorporating premium 800 series rare earth phosphor. For the 60W

lamp, this level requires a 700 series rare earth phosphor.

CSL3, 94.8 lm/W. DOE selected this level because it represents the only viable 60W

replacement that would operate on a 75W ballast with the same CCT as the baseline lamp

5­25
(4,100K). No lamps at 75W can achieve this CSL. For the 60W lamp, this level requires an

improved 700 series rare earth phosphor.

CSL4, 98.2 lm/W. At this level, ballast changes may be required for those users who need

a lamp with a CCT of 4,100K, since only 4,100K T8 lamps are compliant. T8 lamps transition

from a 700 series rare earth phosphor at CSL3 to an 800 series rare earth phosphor.

CSL5, 101.5 lm/W. At this level, ballast changes are required for T8 technology. Also, at

this level the phosphor being used is the premium 800 series rare earth phosphor. This level

represents the highest efficacy level available, or max­tech for 8­foot single pin slimline lamps.

Table 5.3.11. Summary of the CSLs for Eight­Foot Single Pin Fluorescent Lamps

Candidate Standard Level Efficacy Requirement

lm/W

CSL1 87.3

CSL2 92.0

CSL3 94.8

CSL4 98.2

CSL5 101.5

Figure 5.3.14 illustrates the five CSLs on a plot of selected fluorescent lamps. A line at

80.0 lm/W denotes the existing energy conservation standard (from EPACT). Square boxes and

labels identify the two baseline lamps. The plot shows the replacement lamps DOE considered.

Some are the same wattage, but have a higher efficacy; others have lower wattage and higher

efficacy so that the lamp­and­ballast system maintains light output at no less than 10 percent of

the baseline lamp­and­ballast system.

5­26
CSL1

CSL2

CSL3

CSL4

CSL5

EPACT 1992

75W T12 Baseline

60W T12 Baseline

59W T8 Baseline

8­foot T8 single pin slimline 8­foot T12 single pin slimline

R

ate

d

L

a

m

p

Effic

a

c

y (lm/W) 105.0

103.0

101.0

99.0

97.0

95.0

93.0

91.0

89.0

87.0

85.0

83.0

81.0

79.0

77.0

75.0

52 54 56 58 60 62 64 66 68 70 72 74 76 78

Rated Wattage (W)

Figure 5.3.14 Eight­Foot Single Pin Slimline Fluorescent Lamp Candidate Standard Levels

Table 5.3.12 provides detailed information on the 8­foot single pin slimline lamp designs

used in the engineering analysis and subsequent analyses.

5­27
Table 5.3.12 8­Foot Single Pin Slimline Lamp Designs

CSL

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial Light

Output

Mean Light

Output Life CRI

W W lm/W lm lm hr

Baseline/0 T12 75 75 75.0 85.6 6,420 5,906 70

1 T12 75 75.0 87.3 6,550 6,157 12,000 80

Baseline/1 T12 60 60.5 87.6 5,300 4,664 12,000 62

2 T12 75 75.0 92.0 6,900 6,370 15,000 80

2 T12 60 60.5 92.6 5,600 5,152 12,000 70

Baseline/3 T8 59 60.1 94.8 5,700 5,130 15,000 75

3 T12 60 60.5 97.5 5,900 5,480 15,000 73

4 T8 59 60.1 98.2 5,900 5,428 15,000 82

5 T8 59 60.1 101.5 6,100 5,795 18,000 85

5 T8 57 57.0 101.8 5,800 5,450 24,000 81

5 T8 55 55.0 103.6 5,700 5,415 18,000 82

Section 5.3.2.4 presents detailed information about the lamp and ballast systems DOE

develops in the engineering analysis.

5.3.2.3 System Power Rating

For each lamp wattage and ballast type, DOE linearly fits the system power rating of a

lamp on several different ballasts with varying BFs.

Figure 5.3.15 to Figure 5.3.16 show the linear fit and ballast characteristics DOE uses to

derive the system power rating for 2­lamp, 8­foot single pin slimline T12 lamps on electronic

ballasts. The fit follows the form of Eq. 5.1 where SPR = m * BF + b . The ballasts DOE chooses

for these calculations typically have a THD less than 20 percent, PF greater than 0.95, and

typical BEF. Because ballast efficiencies naturally increase as lamp wattages decrease, one sees

a natural progression to higher typical BEFs at lower wattages.

5­28
B

alla

st F

a

ctor 142.0

140.0

138.0

136.0

134.0

132.0

130.0

128.0

126.0

0.78 0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94

ANSI Input Power (W)

Figure 5.3.15 Two­Lamp 75W T12 120V Ballasts with THD <20 percent, PF >0.95, and

BEF 0.64­0.66; Linear Fit: m=100.0, b=47.0

116.0

114.0

S

y

ste

m

P

o

w

er R

atin

g (W) 112.0

110.0

108.0

106.0

104.0

102.0

100.0

0.78 0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94

Ballast Factor

Figure 5.3.16 Two­Lamp 60W T12 120V Ballasts with THD <20 percent, PF >0.95, and

BEF 0.79­0.80; Linear Fit: m=100.0, b=22.0

5­29
Figure 5.3.17 to Figure 5.3.19 show the linear fit and ballast characteristics DOE uses to

derive the system power rating for two­lamp, 8­foot single pin slimline T8 lamps on electronic

ballasts. The ballasts DOE uses for these calculations typically have a THD less than 20 percent,

PF greater than 0.95, and typical BEF. Because ballast efficiencies naturally increase as lamp

wattages decrease, one sees a natural progression to higher typical BEFs at lower wattages.

Also, because there is less manufacturer literature on system power ratings of ballasts with lower

wattage lamps, DOE uses fewer points to develop a linear fit at the energy saving lamp wattages.

0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30

Ballast Factor

Figure 5.3.17 Two­Lamp 59W T8 120V Ballasts with THD <20 percent, PF >0.95, and

BEF 0.77­0.79; Linear Fit: m=123.4, b=4.3

100.0

110.0

120.0

130.0

140.0

150.0

160.0

S

y

ste

m

P

o

w

er R

atin

g (W)

5­30
S

y

ste

m

P

o

wer

R

atin

g (W) 108.0

107.5

107.0

106.5

106.0

105.5

105.0

0.84 0.85 0.86 0.87

Ballast Factor

0.88 0.89

Figure 5.3.18 Two­Lamp 57W T8 120V Ballasts with THD <20 percent, PF >0.95, and

BEF 0.80­0.81; Linear Fit: m=50.0, b=63.5

150

140

0.70 0.80 0.90 1.00 1.10 1.20

Ballast Factor

S

y

ste

m

P

o

w

er R

atin

g (W) 130

120

110

100

90

80

Figure 5.3.19 Two­Lamp 55W T8 120V Ballasts with THD <10 percent, and BEF 0.86;

Linear Fit: m=118.4, b=­2.2

5­31
5.3.2.4 Results

DOE is evaluating three baseline lamps for the 8­foot single pin slimline product class: a

75W T12 lamp, a 60W T12 lamp, and a 59W T8 lamp. For each baseline lamp, DOE considers

both direct­replacement lamps that operate on the existing ballast and lamp­and­ballast

replacement designs that result in approximately the same light output as the baseline lamp. As

discussed earlier, DOE adjusts the BF so that the light output of the lamp­and­ballast design

system never drops below 10 percent of the baseline system.

Table 5.3.13and Table 5.3.14 present the engineering characteristics of the lamp

replacement and lamp­and­ballast replacement designs for the baseline 75W T12, 4,100K lamp

system. Although a 60W T12 lamp is often considered a reduced wattage replacement of the

75W T12 lamp, there are no lamp options with a CCT of 4,100K that emit enough lumens to fall

within 10 percent of the baseline system mean lumens. The highest efficacy 4,100K, 60W T12

lamp replacement is shown below in Table 5.3.13. The light output of this lamp­and­ballast

design is 13 percent less than that of the baseline system. DOE also included lamp­and­ballast

replacement options for a 75W T12, 4,100K lamp. Note that at the higher CSLs, DOE considers

some T8 substitutes for the 75W T12 lamp.

5­32
Table 5.3.13 Lamp Replacement Engineering Analysis for a 75W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor*

System

Power

Rating

System Initial

Light Output

System

Mean Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 75 75.0 85.6 6,420 5,906 12,000 Magnetic 0.94 158.0 12,070 11,103

CSL3 T12 60 60.5 97.5 5,900 5,480 15,000 Magnetic 0.88 126.0 10,384 9,645

*Note: This difference in BFs does not represent a ballast replacement. Rather, the BF of magnetic ballasts changes when the lower wattage lamp is installed.Table 5.3.14 Lamp­and­Ballast Replacement Engineering Analysis for a 75W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 75 75.0 85.6 6,420 5,906 12,000 Magnetic 0.94 158.0 12,070 11,103Baseline T12 75 75.0 85.6 6,420 5,906 12,000 Electronic 0.88 135.0 11,299 10,395

CSL1 T12 75 75.0 87.3 6,550 6,157 12,000 Electronic 0.85 132.0 11,135 10,467CSL2 T12 75 75.0 92.0 6,900 6,370 15,000 Electronic 0.85 132.0 11,730 10,829CSL3 T8 59 60.1 94.8 5,700 5,130 15,000 Electronic 1.18 149.9 13,452 12,107CSL5 T8 59 60.1 101.5 6,100 5,795 18,000 Electronic 0.88 112.8 10,736 10,199

5­33
Table 5.3.15 presents the engineering analysis results for the replacement lamp­and­ballast combinations for the 60W T12

baseline lamp. DOE has not identified any lower­wattage direct lamp replacement designs that could operate on the same ballast as a

60W T12 and save energy. In this table, DOE considers T8 lamp­and­ballast replacements for the baseline lamp, and selects the BFso that the light output of the new system never drops below 10 percent of the baseline system.Table 5.3.15 Lamp­and­Ballast Replacement Engineering Analysis for a 60W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 60 60.5 87.6 5,300 4,664 12,000 Magnetic 0.88 126.0 9,328 8,209Baseline T12 60 60.5 87.6 5,300 4,664 12,000 Electronic 0.88 110.0 9,328 8,209

CSL2 T12 60 60.5 92.6 5,600 5,152 12,000 Electronic 0.85 107.0 9,520 8,758CSL3 T12 60 60.5 97.5 5,900 5,480 15,000 Electronic 0.85 107.0 10,030 9,316CSL3 T8 59 60.1 94.8 5,700 5,130 15,000 Electronic 0.88 112.8 10,032 9,029CSL4 T8 59 60.1 98.2 5,900 5,428 15,000 Electronic 0.78 100.4 9,204 8,468CSL5 T8 57 57.0 101.8 5,800 5,450 24,000 Electronic 0.78 102.5 9,048 8,502CSL5 T8 59 60.1 101.5 6,100 5,795 18,000 Electronic 0.78 100.4 9,516 9,040

Table 5.3.16 and Table 5.3.17 present the engineering analysis results for the lamp replacement and lamp­and­ballast

replacement options for the 59W T8 baseline lamp. In Table 5.3.16, no lamp replacement options at CSL4 are shown because thesystem lumens of reduced wattage lamp replacement options below this CSL are more than 10 percent less than that of the baselinesystem (Table 5.3.14). For lamp­and­ballast replacement combinations, DOE is selecting the BF so that the light output of the newsystem is equal to, greater than, or no more than 10 percent less than the light output of the baseline system.

5­34
Table 5.3.16 Lamp Replacement Engineering Analysis for a Two­Lamp, 59W, T8, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline/CSL3 T8 59 60.1 94.8 5,700 5,130 15,000 Electronic 0.88 112.8 10,032 9,029

CSL5 T8 57 57.0 101.8 5,800 5,450 24,000 Electronic 0.88 107.5 10,208 9,592CSL5 T8 55 55.0 103.6 5,700 5,415 18,000 Electronic 0.88 102.0 10,032 9,530

Table 5.3.17 Lamp­and­Ballast Replacement Engineering Analysis for a Two­Lamp, 59W, T8, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage Rated

Wattage*

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline/CSL3 T8 59 60.1 94.8 5,700 5,130 15,000 Electronic 0.88 112.8 10,032 9,029

CSL4 T8 59 60.1 98.2 5,900 5,428 15,000 Electronic 0.85 109.1 10,030 9,228CSL5 T8 57 57.0 101.8 5,800 5,450 24,000 Electronic 0.85 106.0 9,860 9,265CSL5 T8 59 60.1 101.5 6,100 5,795 18,000 Electronic 0.78 100.4 9,516 9,040CSL5 T8 55 55.0 103.6 5,700 5,415 18,000 Electronic 0.88 102.0 10,032 9,530

5­35
5.3.3 Eight­Foot Recessed Double Contact HO

5.3.3.1 Baseline Models

The 8­foot recessed double contact HO lamps are manufactured in both T8 and T12

diameters. As discussed in Chapter 3, the T12 diameter represents the majority of HO lamp

shipments today and will continue to represent the majority in 2011. Therefore, DOE is

selecting its baseline models for this product class from the T12 diameter, which represents the

most popular lamp type.

The two most popular wattages associated with the 8­foot T12 HO lamp type are the

95W and 110W. For the 95W lamp, the cool white halophosphor lamp is the most popular.

Therefore, DOE is selecting this lamp as the baseline 95W lamp. For the 110W T12 lamp, the

most common lamp purchased uses a rare earth 700 series phosphor. The efficacy of both

baseline lamps is approximately 2 lm/W greater than the EPACT 1992 standard level of 80

lm/W, but no other lamps met the EPACT 1992 CRI requirements, which are lower than either

baseline lamp. As with the baseline fluorescent lamps, DOE is selecting a CCT of 4,100K

because it is the most common CCT for this lamp type.

The typical operating lifetime for these lamps is the same as that of the 8­foot single pin

slimline T12 lamps. The lamp lifetime is typically 12,000 hours. Lamps with a 15,000­hour

lifetime on a 3­hour cycle are marketed as extended performance products. Therefore, DOE is

using a lifetime of 12,000 hours for a 3­hour cycle for the baseline unit of analysis.

The most common ballast used for 8­foot recessed double contact HO T12 lamps is a

rapid start, 120V, electronic ballast with a power factor of 0.90. Together, the 110W T12

baseline lamp­and­ballast combination creates a lumen package of almost 14,660 mean lumens

(and 16,290 initial lumens), while the 95W T12 baseline lamp­and­ballast combination creates a

lumen package of approximately 12,510 mean lumens (and 14,400 initial lumens).

Table 5.3.18 Baseline Units of Analysis for Eight­Foot Linear High­Output Lamps

Lamp

Diameter

Nominal

Wattage CRI CCT RatedEfficacy*

Initial Light

Output

Mean Light

Output Life

W K lm/W lm lm hr

T12 110 70 4,100 80.1 9,050 8,145 12,000

T12 95 62 4,100 82.5 8,000 6,950 12,000

* Rated efficacy is based on the rated wattage of the lamps, which is 97W for the 95W T12 and 113W for the 110W

T12.

5.3.3.2 Candidate Standard Levels

As with the previous product class, DOE is establishing CSLs around design options that

are consistent across the two baseline lamps. In selecting CSLs, DOE considers two different

paths to energy savings. The first concentrates on reduced wattage replacement lamps that could

be installed in a socket and operate on the existing ballast. These lower­wattage replacement

5­36
lamps have a higher efficacy and therefore produce approximately the same light output as the

baseline lamp (i.e., light output never drops below 10 percent of the baseline system). The other

path to energy savings involves lamps that have the same rated wattage as the baseline lamp, but

operate on a new ballast with a different BF, so system energy is lower. DOE is selecting the BF

with the more efficacious lamp to produce approximately the same light output as the baseline

lamp (i.e., light output never drops below 10 percent of the baseline system).

The following discussion identifies the steps and technologies associated with each CSL

DOE considered. As discussed in the screening analysis (Chapter 4), DOE used design options

with highly emissive electrode coatings, higher efficiency lamp fill gas composition, higher

efficiency phosphors, glass coatings, or higher efficiency lamp diameter to achieve higher

efficacy levels. Because high efficiency phosphors and lamp diameter are common methods to

achieve higher efficacies, DOE has identified the diameter and phosphor associated with each

CSL:

CSL1, 83.2 lm/W. This level requires the 110W baseline lamp to use 800 series rare earth

phosphor.

CSL2, 86.1 lm/W. This level cannot be achieved by any 110W baseline lamp. This level

also requires the 95W lamp to move to a rare earth 700 series phosphor.

CSL3, 87.6 lm/W. This level cannot be achieved by the 110W baseline lamp. For the

95W baseline lamp, this level requires a shift to the 800 series rare earth phosphor..

CSL4, 91.9 lm/W. This level eliminates all T12 lamps, only enabling T8 lamps to

comply, which requires a ballast change. This standard level can be achieved with a 700 series

rare earth phosphor in the T8 lamp.

CSL5, 95.3 lm/W. This level also eliminates all T12 lamps, only enabling T8 lamps to

comply, which requires a ballast change. This standard level represents the highest efficacy level

available, or max­tech for 8­foot recessed double contact HO lamps. This level can only be

achieved with an 800 series rare earth phosphor in the T8 lamp.

Table 5.3.19 Summary of the CSLs for Eight­Foot HO Fluorescent Lamps

Candidate Standard Level Efficacy Requirement

lm/W

CSL1 83.2

CSL2 86.1

CSL3 87.6

CSL4 91.9

CSL5 95.3

Figure 5.3.20 illustrates the five CSLs on a plot of selected fluorescent lamps. A line at

80.0 lm/W denotes the existing energy conservation standard (from EPACT 1992). Square

boxes and labels identify the two baseline lamps. The plot also shows the high­efficacy

replacement lamps DOE is considering for each baseline lamp. Some are at the same wattage,

5­37
but have a higher efficacy; others have a combination of lower wattage and higher efficacy so

that the light output never drops below 10 percent of the baseline system.

CSL2

CSL3

CSL4

CSL5

EPACT 1992

CSL1

75.0

77.0

79.0

81.0

83.0

85.0

87.0

89.0

91.0

93.0

95.0

97.0

99.0

101.0

103.0

105.0

R

ate

d

L

a

m

p

Effic

a

c

y (lm/W)

8­foot T8 recessed

double contact HO

8­foot T12 recessed

double contact HO

95W T12 Baseline 110W T12 Baseline

80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116

Rated Wattage (W)

Figure 5.3.20 Eight­Foot HO Fluorescent Lamp Candidate Standard Levels

Table 5.3.20 provides detailed information on the 8­foot recessed double contact high

output lamp designs used in the engineering analysis and subsequent analyses.

5­38
Table 5.3.20 8­Foot Recessed Double Contact High Output Lamp Designs

CSL

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial Light

Output

Mean Light

Output Life CRI

W W lm/W lm lm hr

Baseline/0 T12 110 113 80.1 9,050 8,145 12,000 70

Baseline/0 T12 95 97 82.5 8,000 6,950 12,000 62

1 T12 110 113 83.2 9,400 8,648 12,000 80

2 T12 95 97 86.1 8,350 7,515 12,000 70

3 T12 95 97 87.6 8,500 7,650 12,000 80

3 T12 95 97 88.9 8,625 7,750 12,000 85

3 T8 86 86 93.0 8,000 7,200 18,000 78

4 T8 86 86 93.0 8,000 7,200 18,000 75

5 T8 86 86 95.3 8,200 7,800 18,000 86

Section 5.3.3.4 presents detailed information on the lamp­and­ballast systems DOE

develops in the engineering analysis.

5.3.3.3 System Power Rating

For each lamp wattage and ballast type, DOE linearly fits the system power rating of a

lamp on several different BFs versus the BF of each ballast. Figure 5.3.21 to Figure 5.3.22 show

the linear fit and ballast characteristics DOE uses to derive the system power rating for twolamp, 8­foot T12 recessed double contact HO lamps on electronic ballasts. The fit follows the

form of Eq. 5.1 where SPR = m * BF + b. The ballasts DOE chooses for these calculations

typically have a THD less than 20 percent, PF greater than 0.95, and typical BEF. Because

ballast efficiencies naturally increase as lamp wattages decrease, one sees a natural progression

to higher typical BEFs at lower wattages.

S

yte

m

P

o

w

er R

atin

g (W) 220.0

215.0

210.0

205.0

200.0

195.0

190.0

185.0

0.83 0.85 0.87 0.89 0.91

Ballast Factor

5­39
Figure 5.3.21 Two­Lamp 110W T12 120V Ballasts with THD <20 percent, PF >0.95, and

BEF 0.42­0.43; Linear Fit: m=307.7, b=­65.4

S

y

ste

m

P

o

wer

R

atin

g (W) 190.0

185.0

180.0

175.0

170.0

165.0

160.0

155.0

0.84 0.85 0.86 0.87 0.88 0.89 0.90

Ballast Factor

Figure 5.3.22 Two­Lamp 95W T12 120V Ballasts with THD <20 percent, PF >0.95, and

BEF 0.48­0.52; Linear Fit: m=433.3, b=­204.3

Figure 5.3.23 shows the linear fit and ballast characteristics DOE uses to derive the

system power rating for two­lamp, 8­foot T8 recessed double contact HO lamps on electronic

ballasts. The ballasts DOE uses for these calculations typically have a THD less than 20 percent,

PF greater than 0.95, and typical BEF.

5­40
S

y

stem

P

o

w

er R

atin

g (W) 165.0

163.0

161.0

159.0

157.0

155.0

153.0

151.0

149.0

147.0

145.0

0.8 0.82 0.84 0.86 0.88 0.9

Ballast Factor

Figure 5.3.23 Two­Lamp 86W T8 120V Ballasts with THD <20 percent, PF >0.95, and

BEF 0.54­0.55; Linear Fit: m=128.6, b=46.9

5.3.3.4 Results

DOE is evaluating two baseline lamps for the 8­foot recessed double contact HO product

class: a 110W T12 lamp and a 95W T12 lamp. For each baseline lamp, DOE considers only

energy­saving options that result in approximately the same light output as the baseline lamp.

Energy savings can either be achieved through lamp replacements or lamp­and­ballast

replacements. Additional lamp­and­ballast designs that DOE uses in the NIA are available in

Appendix 5A.

Table 5.3.21 and Table 5.3.22 present the engineering characteristics of lamp

replacement and lamp­and­ballast replacement designs for a baseline 110W T12, 4,100K lamp.

There are no lamp replacement designs at CSL1 because the system lumens of the 95W lamp

replacement options below CSL2 emit less than 10 percent of the baseline system.

For lamp­and­ballast replacement options, DOE considers some T8 substitutes for the 110W T12

lamp at higher CSLs. For the new construction and renovation event, some of these T8 systems

must be spaced closer together so that the potential light output is equal to, greater than, or no

more than 10 percent less than the light output of the baseline system.

.

As discussed earlier, DOE also adjusts the BF such that the system light output of the

lamp­and­ballast design is equal to, greater than, or no more than 10 percent less than the light

output of the baseline system.

5­41
Table 5.3.21 Lamp Replacement Engineering Analysis for a 110W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 110 113 80.1 9,050 8,145 12,000 Electronic 0.90 211.5 16,290 14,661

CSL2 T12 95 97 86.1 8,350 7,515 12,000 Electronic 0.90 185.6 15,030 13,527CSL3 T12 95 97 87.6 8,500 7,650 12,000 Electronic 0.90 185.6 15,300 13,770

Table 5.3.22 Lamp­and­Ballast Replacement Engineering Analysis for a 110W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 110 113 80.1 9,050 8,145 12,000 Electronic 0.90 211.5 16,290 14,661

CSL1 T12 110 113 83.2 9,400 8,648 12,000 Electronic 0.88 205.4 16,544 15,220CSL2 T12 95 97 86.1 8,350 7,515 12,000 Electronic 0.88 177.0 14,696 13,226CSL3 T12 95 97 87.6 8,500 7,650 12,000 Electronic 0.88 177.0 14,960 13,464CSL3 T12 95 97 88.9 8,625 7,750 12,000 Electronic 0.88 177.0 15,180 13,640

CSL4* T8 86 86 91.9 7,900 7,100 24,000 Electronic 0.88 160.0 13,904 12,496CSL4* T8 86 86 93.0 8,000 7,200 18,000 Electronic 0.81 151.0 12,960 11,664

CSL5 T8 86 86 95.3 8,200 7,800 18,000 Electronic 0.88 160.0 14,432 13,728CSL5 T8 86 86 95.3 8,200 7,800 18,000 Electronic 0.81 151.0 13,284 12,636

* These systems are used only in the new construction/renovation scenario in the LCC analysis. Under this event, 1.17 of these systems are installed where therewould have been one baseline system to be within 10 percent mean lumens of the baseline system. Therefore, the LCC and lumen output of these systems are

multiplied by a factor of 1.17 in the LCC analysis.

Table 5.3.23 presents the engineering analysis results for the replacement lamp­and­ballast combinations for the 95W T12

baseline lamp. DOE has not identified any lower­wattage direct lamp replacement designs that could operate on the same ballast as a

5­42
95W T12 and save energy. In this table, DOE considers T8 lamp­and­ballast replacements for the baseline lamp, and selects the BF

so that the new system has a light output of no less than 10 percent of the baseline system.Table 5.3.23 Lamp­and­Ballast Replacement Engineering Analysis for a 95W T12, 4,100K System

Candidate

Standard

Level

Lamp

Diameter

Nominal

Wattage

Rated

Wattage

Rated

Efficacy

Initial

Light

Output

Mean

Light

Output

Life Ballast

Type

Ballast

Factor

System

Power

Rating

System

Initial

Light

Output

System

Mean

Light

Output

W W lm/W lm lm hr W lm lm

Baseline T12 95 97 82.5 8,000 6,950 12,000 Electronic 0.90 185.6 14,400 12,510

CSL1 T12 95 97 86.1 8,350 7,515 12,000 Electronic 0.89 181.3 14,863 13,377CSL2 T12 95 97 87.6 8,500 7,650 12,000 Electronic 0.88 177.0 14,960 13,464CSL3 T8 86 86 91.9 7,900 7,100 24,000 Electronic 0.88 160.0 13,904 12,496CSL3 T8 86 86 93.0 8,000 7,200 18,000 Electronic 0.88 160.0 14,080 12,672CSL4 T8 86 86 95.3 8,200 7,800 18,000 Electronic 0.81 151.0 13,284 12,636

5­43
5.4 INCANDESCENT REFLECTOR LAMPS

As discussed in Chapter 3 of the ANOPR TSD, the market and technology assessments,

DOE is revising the table of product classes for the ANOPR to reflect the utility of these

products and how they are used in the market. DOE is creating two separate product classes:

standard­spectrum IRL and modified­spectrum IRL. Because modified­spectrum lamps make up

a small percentage of the market, DOE is choosing to analyze the standard­spectrum IRL product

class and intends to extrapolate its findings to the modified­spectrum product class. Section 5.5

provides detail on this extrapolation.

Each IRL product class considered spans the full range of wattages covered. DOE is

considering CSLs for each product class with efficacy varying with wattage. Given that IRL

product classes are no longer divided by wattage, DOE is not choosing a representative wattage

bin for IRL. However, rather than selecting one baseline lamp, DOE is choosing to analyze

lamps of multiple wattages in the standard­spectrum product class to prevent oversimplification

of the analysis. DOE is concentrating its resources on analyzing the most popular reflector

lamps in terms of lamp size, wattage, and lumen package. DOE is examining existing product

on the market at multiple wattages to select baseline lamps. DOE uses product at multiple

wattages to derive efficacy equations that span wattage. Therefore, DOE is able to apply the

analysis performed on the most popular lamps to the other, less common lamps. Section 5.4.2

provides further detail on the CSLs DOE is developing for IRL.

Table 5.4.1 Product Classes for Incandescent Reflector Lamps

Lamp Category Standard­Spectrum Modified­Spectrum

Reflector Lamps Representative Product Class Scaled from Standard Spectrum IRL

As with GSFL, DOE analyzes lamp designs for the LCC that both save energy and

maintain comparable light output. DOE considers lamp designs that emit initial lumens equal to

the light output of the baseline system, or less than that system, but by no more than 10 percent.

DOE maintains light output across efficacy levels to ensure that products supply equivalent

service under the base case and standards case scenarios. To account for the purchase of more

efficacious lamps at constant wattage (with greater light output), DOE considers non­energy

saving lamps in the NIA. Appendix 5A shows lamp designs considered in the NIA.

In assessing light output, DOE distinguishes between mean and initial lumens. DOE uses

initial lumens in its test procedures for incandescent lamps to measure compliance with a

standard. This is consistent with consensus industry standards on efficacy measurements.

Therefore, DOE uses initial lumens to calculate efficacy. For incandescent lamps, DOE also

uses initial lumens when predicting consumer purchase decisions. Consumers generally make

purchase decisions based on initial lumens and not mean lumens for incandescent lamps.

Therefore, DOE lists initial lumens in its tables. Over time, the light output of an incandescent

lamp decreases slightly. To account for this real­world depreciation in lumens, DOE also

monitors mean lumens in the NIA.

5­44
5.4.1 Baseline Models

DOE is selecting three baseline lamps of varying wattage and shapes to provide a

comprehensive understanding of consumer economics. DOE includes parabolic reflector (PAR)

halogen baseline lamps of three different wattages. These baseline lamps are currently regulated

by EPCA and meet the EPCA standard.

DOE has identified three IRL lumen packages that are popular in the commercial and

residential sectors. DOE has also identified power ratings and lifetime characteristics of these

lamps, as listed in Table 5.4.2. The three light output packages are 580, 1050, and 1,310 lumens,

corresponding to a 50W PAR30, 75W PAR38, and 90W PAR38 lamp. DOE believes these

lamps represent a good cross­section of the most common reflector lamps sold and used today.

Since these lamps capture a range of wattages, lumen packages, and lamp diameters, they cover a

range of applications. Table 5.4.2 presents the representative product class and the three baseline

lamps DOE is selecting for its IRL analysis. DOE believes that these lamps represent highvolume wattages and diameters.

Table 5.4.2 IRL Representative Product Class and Baseline Lamps

Lamp Representative

Representative Product Class

Baseline Lamps

Category Product Class

Descriptor

Wattage

W

Efficacy

lm/W

Initial Light Output

lm

Lifetime

hr

IRL StandardSpectrum

PAR30

PAR38

PAR38

50

75

90

11.6

14.0

14.6

580

1,050

1,310

3,000

2,500

2,500

5.4.2 Candidate Standard Levels

For IRL, DOE has observed natural efficacy divisions in the marketplace corresponding

to a variety of design options to increase lamp efficacy. DOE considers these efficacy divisions

in selecting CSLs by using the efficacy levels of commercially available lamps as a guide.

However, commercially available product does not exist at all of the CSLs for all of the baseline

lamps. For example, the 75W PAR38 baseline lamp with 1,050 lumens has commercially

available products at all three CSLs, but the 50W PAR30 baseline lamp with 580 lumens only

has commercially available product at one of the three CSLs. Because it is technically feasible

to incorporate the commercially available technologies in lamp types that correspond to all of the

baseline lamps, and to have a continuous range of efficacies to analyze, DOE is developing some

model IRL based on commercially available lamp lumen packages. Using efficacy information

for the commercially available lamp designs (which substitute for certain baseline lamps), DOE

can develop a relationship of efficacy to wattage. This allows DOE to develop lamp designs that

are not commercially available for certain wattages, but that would be substitutes for other

baseline lamps. DOE assumes that in the majority of instances, lamps of similar diameters may

substitute for one another. Generally, the lamp design substitutes for baseline lamps are based

around the lumen output of the baseline lamp, plus or minus 10 percent.

In reviewing published catalog data, DOE observes that higher efficacy, reduced­wattage

IRL, which maintain light output within 10 percent, can substitute for a number of baseline

lamps. Furthermore, these reduced­wattage designs span a range of design options available for

5­45
consideration in this rule. These design options, discussed in the screening analysis (Chapter 4),

include the tungsten­halogen regenerative cycle (hereafter “halogen”) and HIR technologies that

uses both halogen and glass coatings that reflect infrared light.

The commercially available halogen IRL fall within two tiers of efficacy. To distinguish

the efficacies of these halogen IRL, DOE designates them as halogen and improved halogen.

DOE also observes two tiers of efficacy for HIR IRL. To distinguish the efficacies of these IRL,

DOE designates them as HIR and improved HIR. Improved HIR and improved halogen can be

achieved by using the additional design options discussed in the screening analysis. These

design options include higher efficiency filaments, efficient filament coiling, filament

configuration, capsule design, high pressure capsules, or higher efficiency reflector coating.

DOE observes lifetime changes across these reduced­wattage IRL. For example, a halogen IRL

typically has a lifetime of around 2,000 to 3,000 hours, while an HIR IRL typically lives for

3,000 to 4,000 hours. DOE maintains the lifetime attributes of the commercially available

product for its analysis.

DOE is establishing CSLs for IRL using an approach similar to the one it uses for GSFL.

DOE is developing continuous equations that set a minimum efficacy requirement across

wattage. Each equation represents the potential efficacy a lamp achieves using a particular

design option. These “technology contour lines” represent the same IRL design option across

the wattage range of a product class. For example, a CSL based on a halogen design option is a

curve rather than a step function, and denotes a halogen standard at all wattages. In general

terms, DOE is basing the CSLs on the following progression of design options:

CSL1. Improved halogen considers moving all reflector lamps to a level that can be

achieved with improved efficacy halogen lamps, such as an improved reflective coating or higher

pressure halogen capsules.

CSL2. HIR considers a level that can be achieved by a halogen capsule with an infrared

reflective coating.

CSL3. Improved HIR considers a level that can be achieved by an improved reflective

coating, better HIR coatings or higher pressure halogen capsules.

Figure 5.4.1 plots the results of the IRL engineering analysis for the three baseline lamps

along with the three CSLs shown in Table 5.4.3. Square boxes and labels represent the three

baseline lamps in the plot; diamonds represent higher efficiency lamp designs. Maintaining light

output on this plot of efficacy versus wattage means that lamp designs are always higher in

efficacy than the baseline lamp (i.e., moving up on the y­axis) and lower in wattage (i.e., moving

to the left on the x­axis). This trend is evident for all three lumen packages analyzed in the LCC.

As illustrated in Table 5.4.4 through Table 5.4.6, the CSLs correspond to efficacy levels

associated with lamps with particular design options.

5­46
Table 5.4.3 Summary of the CSLs for IRL

Candidate Standard Level Incandescent Reflector Lamps

lm/W

CSL1 5.0P0.27

CSL2 5.5P0.27

CSL3 6.2P0.27

P = rated wattage

22.0

20.0

18.0

16.0

14.0

12.0

La

mp Efficacy (lum

ens / w

att) .

Baseline

EPCA

CSL1

CSL2

CSL3

PAR30, 50W

PAR38, 75W

PAR38, 90W

Baseline/EPCA: Halogen (2,500­3,000 hr)

CSL2: Improved Halogen (3,000 hr)

CSL3: HIR (3,000 hr)

CSL4: Improved HIR (4,000 hr)

10.0

30 40 50 60 70 80 90 100 110 120 130

Lamp Power (watts)

Figure 5.4.1 IRL Baselines and Reduced Wattage Options

5.4.3 Results

After selecting baseline lamps and CSLs, DOE selects lamp designs associated with the

CSLs for each of the three baseline lamps. In each case, the halogen pairings use the same

replacement lamps at CSL2, CSL3, and CSL4, as they are all part of the same lumen package

(i.e., 620, 1,000, 1,300). Like GSFL, DOE considers IRL that produce more light but do not

save energy in the NIA. This reflects the fact that DOE cannot require consumers to switch to a

reduced wattage lamp. Appendix 5A shows the characteristics of lamp designs that both meet

the CSL and exhibit a constant or higher wattage than the baseline lamp.

The following table presents the engineering analysis for the 50W PAR30 IRL. This

baseline lamp is based on a 580­lumen lamp, plus or minus 10 percent. Both the 44.3W PAR30

5­47
improved halogen lamp (CSL1) and the 41.3W PAR30 HIR lamp (CSL2) are model lamp

designs.

e These lamps are designed to have the same lumen package as the baseline lamp (i.e.,

580 lumens), and to have a minimum efficacy just equal to CSL1 and CSL2 respectively. The

percentage energy savings and efficacy improvements of the PAR30 lamps are similar to the

energy savings and percentage efficacy improvements of the 1,310­lumen lamps analyzed. The

44.3W improved halogen PAR30 lamp reduces wattage by 11 percent and is 21 percent more

efficacious than the halogen 50W PAR30 baseline lamp. The 41.3W HIR PAR30 lamp reduces

wattage by 17 percent and is 29 percent more efficacious than the 50W PAR30 baseline lamp. In

comparison, the 79W improved halogen PAR38 reduces wattage by 12 percent and is 14 percent

more efficacious than the incandescent 90W PAR38 baseline lamp. The 70W HIR PAR38

reduces wattage by 29 percent and is 23 percent more efficacious than the 90W PAR38 baseline

lamp. The 40W improved HIR PAR30 is commercially available, but produces 17 percent more

light output than the 50W PAR30. Ordinarily, this would not be considered a lamp design for

this baseline lamp. However, because this lamp represents a commercially­available reducedwattage, high­efficacy version of the baseline lamp.

Table 5.4.4 IRL Engineering Analysis 50W PAR30

Candidate

Standard Design Lamp Wattage Efficacy

Initial Light

Output

Lamp

Life

Level Option Descriptor

W lm/W lm hr

Baseline Halogen PAR30 50.0 11.6 580 3,000

CSL1 Improved

Halogen* PAR30 44.3 14.0 620 3,000

CSL2 HIR* PAR30 41.3 15.0 620 3,000

CSL3 Improved HIR PAR30 40.0 17.0 680* 4,000

The following table presents the engineering analysis for the 75W PAR38 IRL. This

baseline lamp and its lamp design substitutes are based on a 1,050­lumen lamp, plus or minus 10

percent. All the lamps shown in the following table are commercially available.

e Model lamp designs represent lamps that are not commercially available at this time. DOE developed these lamps

working from technical literature and confidential information from manufacturers on incandescent design options.

DOE developed these model lamp designs to have a more continuous range of CSLs to analyze across the three

lumen packages. DOE differentiates between model lamp designs and commercially available lamp designs by

showing the wattage of the model lamp design to the tenths decimal place. Commercially available lamps are

shown in the same way they appear in the product catalogs, rounded off to the nearest whole number.

5­48
Table 5.4.5. IRL Engineering Analysis for 75W PAR38

Candidate

Standard

Design

Option

Lamp

Descriptor

Wattage Efficacy Initial Light

Output

Lamp

Life

Level W lm/W lm hr

Baseline Halogen PAR38 75 14.0 1,050 2,500

CSL1 Improved

Halogen

PAR38 66 15.9 1,050 3,000

CSL2 HIR PAR38 60 17.5 1,050 3,000

CSL3 Improved HIR PAR38 55 19.1 1,050 4,000

The following table presents the engineering analysis for the 90W PAR38 IRL. This

baseline lamp and its substitute lamp designs are based on a 1,310­lumen lamp, plus or minus 10

percent. The 66.0W improved HIR PAR38 is a model lamp design. DOE scaled this lamp

design from relationship between the 75W halogen PAR38 and the 55W improved HIR PAR38.

Both the 55W PAR38 commercially available lamp and the 66.0W PAR38 model lamp reduce

wattage by 27 percent relative to their halogen counterparts (i.e., the 75W PAR38 and 90W

PAR38, respectively). In addition, both the 66.0W improved HIR PAR38 model lamp and the

55W improved HIR PAR38 commercially available lamp are 36 percent more efficacious than

their halogen counterparts.

Table 5.4.6 IRL Engineering Analysis for 90W PAR38

Candidate

Standard

Level

Design

Option

Lamp

Descriptor

Wattage Efficacy Initial Light

Output

Lamp

Life

W lm/W lm hr

Baseline Halogen PAR38 90 14.6 1,310 2,500

CSL1 Improved

Halogen

PAR38 79 16.6 1,310 3,000

CSL2 HIR PAR38 70 18.0 1,260 3,000

CSL3 Improved HIR* PAR38 66 19.8 1,310 4,000

* IRL lamp designs with an asterisk are model lamp designs.

5.5 SCALING TO PRODUCT CLASSES NOT ANALYZED

DOE identifies and selects certain product classes as “representative” product classes

where DOE will concentrate its analytical effort. DOE chooses these representative product

classes primarily due to their high market volumes. The following section discusses how DOE

intends to scale CSLs from those product classes that it analyzes to those product classes that it

does not analyze.

5.5.1 General Service Fluorescent Lamps

As discussed in section 5.3, DOE is not analyzing GSFL with a CCT above 4,500K and

2­foot U­shaped lamps. As discussed in the market and technology assessment , the efficacy of

lamps with cooler CCTs (i.e., higher CCT values) is lower due to the quality of blue light

5­49
emitted. DOE compared commercially available T8 lamps at 4,100K and 6,500K, and found that

the efficacy of the 6,500K lamps was between four and seven percent lower than that of the

4,100K lamps. To avoid overly penalizing current product offered in the market, DOE is

considering adopting the larger of the two scaling factors (seven percent) when determining the

efficacy requirement for lamps greater than 4,500K. This would mean, for example, that if 82.4

lm/W (i.e., CSL1) were selected for the 4­foot medium bipin product class of 4,500K CCT and

below, the scaled efficacy requirement for the product class greater than 4,500K CCT would be

76.6 lm/W.

Similarly, DOE observes that 2­foot U­shaped lamps generally are less efficacious than

4­foot medium bipin lamps due to the bend of a 2­foot U­shaped lamp. This drop in efficacy

appears to depend on the wattage and diameter of the lamp in question. DOE has observed that

40W T12 2­foot U­shaped lamps are on average six percent less efficacious than a 40W T12

medium bipin lamp of the same phosphor series and manufacturer, while 34W T12 or 32W T8 2­

foot U­shaped lamps are generally three percent less efficacious than the 34W T12 or 32W T8

medium bipin lamp of the same phosphor series and manufacturer. To avoid penalizing T12

lamps, DOE is considering applying a six­percent decrease to the CSLs for 4­foot medium bipin

lamps for 2­foot U­shaped lamps.

5.5.2 Incandescent Reflector Lamps

DOE analyzes standard­spectrum lamps, but will set separate standards for modifiedspectrum IRL. As with higher CCT GSFL, modified­spectrum IRL filter portions of the emitted

spectrum to attain a particular spectral emission, thereby lowering their efficacy value.

Modified­spectrum IRL achieve this specific spectrum by applying a coating, or introducing

neodymium or other additives, into the cover glass of the IRL. Because manufacturers may

change the thickness of the coating or the content of neodymium to modify the spectrum to

different degrees, and thus change the lumens the IRL emits, DOE has developed the following

formula to establish the standard level for these modified­spectrum IRL:

lmModified −Spectrum CSLModified −Spectrum = *CSLS tan dard −Spectrumr Eq. 5.2 lmS tan dard −Spectrum

where:

CSLModified­Spectrum = Candidate standard level of modifiedspectrum lamp

CSLStandard­Spectrum = Candidate standard level of the equivalent

reference standard­spectrum lamp

lmModified­Spectrum = Lumen output of modified­spectrum lamp

lmStandard­Spectrum = Lumen output of the equivalent reference

standard­spectrum lamp

For manufacturers to comply with the energy conservation standard for modifiedspectrum IRL, they would be required to test the lumen output of both their modified­spectrum

5­50
lamp as well as the lumen output of an equivalent reference standard­spectrum lamp. (An

equivalent lamp would have the same rated wattage, rated voltage, gas fill pressure and

composition, bulb shape and size, filament type and orientation, finish and other design features

incorporated into the modified­spectrum lamp, but without the coating or neodymium (or other

additive) that causes the lamp to emit a modified­spectrum.) Manufacturers could then apply

that ratio of lumen output to the energy conservation standard for a standard­spectrum IRL to

calculate the standard for modified­spectrum IRL. In this way, the consumer would be assured

that the design options that DOE found to be cost­justified in this rulemaking for standardspectrum IRL would also be incorporated into covered modified­spectrum IRL.

5­51
REFERENCES

1 National Electrical Manufacturers Association. 2006. No. 12 at p. 7. This written comment,

Document Number 12, is available in Docket #EE–2006–STD–0131. For more information,

contact Brenda Edwards­Jones at (202) 586­2945.

2 U.S. Department of Energy, Energy Efficiency and Renewable Energy Office of Building

Research and Standards. U.S. Department of Energy, Office of Energy Efficiency and

Renewable Energy. Energy Conservation Program for Consumer Products: Technical Support

Document: Energy Efficiency Standards for Consumer Products: Fluorescent Lamp Ballast

Proposed Rule. Appendix B. Marginal Energy Prices and National Energy Savings. Table B.6.

January, 2000. Washington, D.C.

<http://www.eere.energy.gov/buildings/appliance_standards/residential/pdfs/appendix_b.pdf.

5­52