9-i CHAPTER 9. TRIAL STANDARD LEVELS

TABLE OF CONTENTS

9.1 INTRODUCTION ........................................................................................................... 9-1

9.2 GENERAL SERVICE FLUORESCENT LAMPS.......................................................... 9-1

9.2.1 Representative Product Classes ...........................................................................9-1

9.2.2 Trial Standard Levels........................................................................................... 9-2

9.3 INCANDESCENT REFLECTOR LAMPS..................................................................... 9-4

9.3.1 Representative Product Classes ...........................................................................9-4

9.3.2 Trial Standard Levels........................................................................................... 9-4

LIST OF TABLES

Table 9.1 Product Classes for GSFL........................................................................................... 9 -2

Table 9.2 Trial Standard Levels for G SFL, Represented by Efficacy Levels ............................ 9-2

Table 9.3 Trial Standard Levels for GSFL, as Shown by Efficacy Values ................................9-2

Table 9.4 Product Classes for IRL............................................................................................. . 9-4

Table 9.5 Trial Standard Levels for IRL, as Shown by Efficacy Levels....................................9-5

Table 9.6 Trial Standard Levels for IRL, as Shown by Efficacy Values....................................9-59-1 CHAPTER 9. TRIAL STANDARD LEVELS

9.1 INTRODUCTION

The U.S. De partment of Energy (DOE) gene rated national energy savings (NES) and net present value (NPV) results based on trial stan dard levels (TSLs). The TSLs designate an efficacy level (EL) for each product class. ELs are developed for each product class in the engineering analysis. In this chapter, DOE is only presenting the TSLs of the product classes that DOE analyzed directly (the “representativ e product classes”). Chapter 5 of the TSD and

section V.A.1 of the final rule Federal Register notice discuss product classes in greater detail.

DOE then scaled the standards fo r the representative product classe s to create standards for other product classes that were not directly analyzed.

9.2 GENERAL SERVICE FLUORESCENT LAMPS

9.2.1 Representative Product Classes

The following lam ps with a color correlate d temperature (CCT) less than 4,500 kelvin (K) compose the five representative product classe s for GSFL: (1) 4-foot medium bipin (MBP); (2) 8-foot single pin (SP) slim line; (3) 8-foot recessed double contact (RDC) high output (HO) lamps; (4) 4-foot miniature bipin (MiniBP) T5 standard output (SO); and (5) 4-foot miniature MiniBP T5 HO lamps. Details on how these pr oduct classes were selected can be found in chapter 5 of the TSD. Table 9.1 shows all GSFL product classe s and designates those which were considered to be representative.9-2 Table 9.1 Product Classes for GSFL

Lamp Type For CCT ≤ 4,500K Minimum Lamp Efficacy

lm/W* For CCT > 4,500K Minimum Lamp Efficacy

lm/W

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

2-foot U-shaped Scaled from 4-foot medium bipin Scaled from ≤ 4,500K

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

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

4-foot T5 miniature bipin SO Representative product class Scaled from ≤ 4,500K

4-foot T5 miniature bipin HO Representative product class Scaled from ≤ 4,500K

* lm/W = lumens per watt

9.2.2 Trial Standard Levels

DOE developed TSLs that generally follow a trend of increasing efficacy by using higher quality phosphors. The TSLs also represent a general move from higher wattage technologies to lower wattage, smaller diameter lamps with highe r efficacies. DOE analyzes systems that meet each efficacy level in the TSLs by pairing stan dard and reduced-wattage lamps featuring a variety of design options with a ppropriate magnetic or electronic ballasts. As discussed in the screening analysis (chapter 4), DOE uses design options with highl y emissive electrode coatings, higher efficiency lamp fill gas composition, higher efficiency phosphors, glass coatings, or lamp diameter to achieve higher efficacy levels. Th e TSLs for the five representative GSFL product

classes are shown in Table 9.2 and Table 9.3

.

Table 9.2 Trial Standard Levels for GS FL, Represented b y Efficacy Levels Representative Product Class TSL 1 TSL 2 TSL 3 TSL 4 TSL 5 4-Foot Medium Bipin, CCT ≤ 4,500K EL1 EL2 EL3 EL4 EL5 8-Foot Single Pin Slimline, CCT ≤ 4,500K EL1 EL2 EL3 EL4 EL5 8-Foot RDC HO, CCT ≤ 4,500K EL1 EL2 EL3 EL4 EL5 4-Foot Miniature Bipin T5 SO, CCT ≤ 4,500K EL1 EL1 EL1 EL1 EL2 4-Foot Miniature Bipin T5 HO, CCT ≤ 4,500K EL1 EL1 EL1 EL1 EL1

Table 9.3 Trial Standard Levels for GSFL, as Shown by Efficacy Values Representative Product Class TSL 1 TSL 2 TSL 3 TSL 4 TSL 5 4-Foot Medium Bipin, CCT ≤ 4,500K 78 81 85 89 93 8-Foot Single Pin Slimline, CCT ≤ 4,500K 86 92 95 97 98
8-Foot RDC HO, CCT ≤ 4,500K 83 86 88 92 95 4-Foot Miniature Bipin T5 SO, CCT ≤ 4,500K 86 86 86 86 90 4-Foot Miniature Bipin T5 HO, CCT ≤ 4,500K 76 76 76 76 76

TSL1, which would set energy conservation st andards for GSFL to EL1 for all product classes, would eliminate the 4-foot MBP T12 ba selines, the 95W T12 8-fo ot RDC HO baseline,9-3 and the 75W T12 8-foot single pin slimline baseline from the market. In the 4-foot MBP product class, this TSL could be met either with a 40W T12 lamp using improved 700-series or 800- series phosphors, or with a 34W T12 lamp us ing a 700-series phosphor. A 4-foot MBP lamp using only halophosphors would not be able to meet this TSL. The 75W 8-foot SP slimline T12 and 110W RDC HO lamps would need to use an 800- series rare earth phosphor to meet TSL1. TSL1 also represents a level which would lik ely prevent the commercialization of T5 lamps which halophosphor coating while allowing for 800- series 4-foot T5 MiniBP and 4-foot T5 MiniBP HO lamps that are currently commerc ially available to remain on the market.

TSL2 would set energy conservation standards for GSFL at EL2 for 4-foot MBP, 8-foot SP slimline, and 8-foot RDC HO lamps. Th e 34W T12 4-foot MBP lamps would likely be required to use 800-series rare earth phosphors to meet TSL2. For 40W T12 lamps, TSL2 is expected to require a premium 800-series rare earth phosphor a nd is the maximum TSL that a

40W T12 would be able to meet. In the 8-foot SP slimline product class, TSL2 is expected to require a premium 800-series rare earth phosphor for the 75W T12 and is the maximum TSL that 75W T12 would likely be able to meet. This standard level would eliminate the 60W T12 baseline and require a 700-series phosphor for th is lamp. In the 8-foot RDC HO product class, TSL2 would eliminate 110W T12 lamps and the 95W T12 baseline and woul d require rare earth 700-series phosphors for 95W T12 lamps. For T5s, TS L2 still represents the first efficacy level, which would allow for 800-series 4-foot T5 MiniBP and 4-foot T5 MiniBP HO lamps to remain

on the market.

TSL3 would set energy conservation standards for GSFL at EL3 for 4-foot MBP, 8-foot SP slimline, and 8-foot RDC HO lamps. In this product class, the 32W T8 baseline would be eliminated from the market. To produce a TS L3-compliant 32W T8 lamp, manufacturers would need to use an 800-series rare earth phosphor. The 34W T12 lamps would likely require an improved 800-series rare earth phosphor mixture and possibly other design options, such as a different gas fill or increased thickness of th e bulb-wall phosphor. Only reduced-wattage (34W) 4-foot MBP T12 lamps are expected to meet this TSL. In the 8-foot SP slimline product class, TSL3 would require the use of an 800-series 60W T 12 lamp. This standard level is expected to eliminate all 75W T12 lamps and require an im proved 700-series phosphor for the 60W T12. In the 8-foot RDC HO class, TSL3 requires 95W T12 lamps to shift to 800-series rare earth phosphors. TSL3 also represents the first effica cy level for 4-foot T5 MiniBP and 4-foot T5 MiniBP HO lamps, retaining 800-series ve rsions of those lamps on the market.

TSL4, which would set energy conservation sta ndards for GSFL at EL4 for 4-foot MBP, 8-foot SP slimline, and 8-foot RDC HO, is e xpected to eliminate 4,100K T12 lamps from the marketplace. TSL4 is also exp ected to raise the efficacy of a ll full-wattage T8 lamps above the baselines for the aforementioned product classes. In the 4-foot MBP product class, TSL4 could be met by improved 800-series full-wattage T8 la mps, or by 800-series 30 W and 25W T8 lamps. For the 8-foot SP slimline product class. 59W T8 lamps would likely need to use an 800-series rare earth phosphor to meet TSL4. TSL4, wh ile expected to eliminate 8-foot T12 RDC HO lamps from the market, would require an improved 700-series mixture to be used in T8 lamps for this product class. TSL4 also represents the fi rst efficacy level for 4-foot T5 MiniBP and 4-foot T5 MiniBP HO lamps, retaining 800-series T5 lamps on the market.9-4 TSL5 represents the max-tech EL for a ll GSFL product classes. T12 lamps and 700- series T8 lamps are expected to not be able to m eet this level. In the 4-foot MBP and 8-foot SP slimline product class, T8 lamps would need to have a premium 800-series rare earth phosphor coating to meet TSL5. TSL5 could also be met by the 28W reduced-wattage 4-foot MBP T8 lamp and the 57W and 55W reduced-wattage 8-foot SP slimline T8 lamps. TSL5 would require movement 800-series T8 lamps in the 8-foot RDC HO product class. For the 4-foot T5 MiniBP SO product class, a standard-wattage (28W) a nd reduced-wattage (26W) T5 with an improved 800-series phosphor would need to be used in order to meet TSL5. Because DOE created only one efficacy level for the 4-foot T5 MiniBP HO lamps, TSL5 would set energy conservation standards 4-foot T5 MiniBP HO lamps at EL1 and allow 800-series T5 HO lamps to remain on

he market. t

9.3 INCANDESCENT REFLECTOR LAMPS

9.3.1 Representative Product Classes

DOE selected standard-spectrum IRL with a di ameter greater than or equal to 2.5 inches and voltage less than 125 volts to be a representative product cl ass for IRL. Representative product classes are discussed in more detail in chapter 5 of the TSD. Table 9.4 lists the IRL product classes.

Table 9.4 Product Classes for IRL

Lamp Type Diameter Voltage

≥ 125 > 2.5 inches < 125 (representative)

≥ 125 Standard Spectrum

≤ 2.5 inches < 125

≥ 125 > 2.5 inches < 125

≥ 125 Modified Spectrum

≤ 2.5 inches < 125

9.3.2 Trial Standard Levels

As discussed in the screening analysis (chapter 4), DOE uses design options with highertemperature operation, thinner filame nts, efficient filament coiling, efficient filament orientation, higher-efficiency inert fill gas, tungsten haloge n lamps, higher pressure tungsten halogen lamps, infrared glass coatings, higher-efficiency reflec tor coatings, integrally ballasted low-voltage lamps, and efficient filament placing to achieve hi gher efficacy levels. The efficacy levels for9-5 the representative IRL product class and the corresponding efficacy values are shown in Table

9.5 and Table 9.6 . Each TSL is comprised of the same num bered efficacy level for all eight IRL product classes. For example, TSL1 contains EL1 for all eight product classes.

Table 9.5 Trial Standard Levels for IRL, as Shown by Efficacy Levels Trial Standard Level (lm/W)*

IRL Product Class TSL1 TSL2 TSL3 TSL4 TSL5 Standard Spectrum, Diameter > 2.5in, Voltage < 125 EL1 EL2 EL3 EL4 EL5

*P is the rated wattage of the lamp.

Table 9.6 Trial Standard Levels for IRL, as Shown by Efficacy Values Trial Standard Level (lm/W)*

IRL Product Class TSL1 TSL2 TSL3 TSL4 TSL5 Standard Spectrum, Diameter > 2.5in, Voltage < 125 4.6P 0.27 4.8P 0.27 5.4P 0.27 5.9P 0.27 6.4P 0.27

*P is the rated wattage of the lamp.

TSL1 considers moving all reflector lamps to a level that could be achieved with improved efficacy halogen lamps using xenon, a higher efficacy inert fill gas. Such a lamp is currently not commercially available at any of the three lumen packages that DOE analyzed, but is technologically feasib le to produce. To create EL1, DOE developed a model of a lamp with xenon gas using information from technical li terature and confiden tial information from

manufacturers.

TSL2 considers a level that could be achieve d by a halogen capsule with an infrared reflective coating and a lamp lifet ime of 6,000 hours. An improved halogen lamp that utilizes a silver reflective coating, ba sed on an improved halogen lamp with a lifetime of 3,000 hours

could also meet this level.

TSL3 considers a level that could be achieve d by a halogen capsule with an infrared reflective coating and a lamp lifetime of 3,000 ho urs. Decreasing the lamp lifetime from 6,000 to 3,000 hours effectively improves the effi ciency of the tungsten filament.

TSL4 considers a level that could be ach ieved by a 4,000-hour-life time improved halogen infrared lamp. Improvements in the halogen infrared lamp may include the use of a doubleended halogen infrared burner, higher-efficiency inert fill gas, or more-efficient filament orientation. DOE also models an EL4 lamp for the Baseline Lifetime scen ario (see chapter 10) that utilizes the same technology but features the same lifetime as th e baseline lamp in each lumen package (2,500 hours, 2,500 hours, and 3,000 hours for the 90W, 75W, and 50W lumen packages, respectively).

TSL5 considers a level that could be achieved with a 4,200-hour-lifetime halogen infrared lamp (even further improved). Th ese further improvements include an improved reflector, improved IR coating, or filament and capsule design that produce higher temperature9-6 operation. DOE also models an EL5 lamp for th e Baseline Lifetime scenario that utilizes the same technology as an EL4 lamp but features a lifetime of 2,500 hours for all lumen packages.