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### Fluorescent Lamp Ballasts

Test Procedure Notice of Proposed Rulemaking Public Meeting

The Department of Ener gy (DOE) is holding a public meeting that will first cover the test procedure notice of proposed rulemaking (NOPR) for fluorescent lamp ballasts and then the energy conservation standards rulemaking for the same products. This public meeting gives DOE an opportunity to present the proposals in the test procedure NOPR and to respond to stakeholder questions. DOE will also seek input from interested parties on the planned methodologies, assumptions, data sources, and the NEMA Alternative Test

Procedure Handout.

The following documents are available as

Adobe Acrobat PDFs. Download Adobe

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Meeting Materials

z Test Procedures for Fluorescent Lamp Ballasts; NOPR, as issued by the Secretary of Energy ( PDF 2.0 MB )

NOTE: The official version of the NOPR will be published in the Federal Register shortly.

z NEMA Alternative Test Procedure EERE Information Center Programs and Offices

DATE: April 26, 2010

TIME: 9:00 a.m. ET
LOCATION: U.S. Department of Energy Forrestal Building

Room 8E-089 1000 Independence Avenue, SW Washington, DC 20585 Pa g e 1 of 3 A pp liances and Commercial E q ui p ment Standards: Fluorescent Lam p Ballasts Test Proce...

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. g ov/buildin g s/a pp liance

_ standards/residential/fluorescent

_ lam p_

...Handout ( PDF 90 KB )

This document outlines a draft NEMA test procedure for the measurement of fluorescent lamp ballast efficiency. DOE summarizes this test procedure

as an alternative method under

consideration in th e fluorescent lamp

ballast active mode test procedure NOPR in section III.E.2. DOE requests

comment on this alternative test

method as noted in section V.E.5 of the test procedure NOPR.

z Test Data, Appendix 5c of the fluorescent lamp ballast energy conservation standard preliminary technical support document ( PDF 234

KB )

z Presentation (available after meeting)

z Agenda (available after meeting)

z Transcript (availabl e after meeting) A transcript will also be available for public inspection in the Building Technologies Program Reading Room, between 9:00 a.m. and 4:00 p.m., Monday through Friday, except Federal holidays. To schedule an appointment or to purchase this transcript, contact:

Brenda Edwards U.S. Department of Energy Building Technologies Program 950 L'Enfant Plaza, 6th Floor Washington, DC 20024

202-586-2945

How to Submit Comments Submit comments electronically, by mail, or by courier. Wherever possible, comments in the electronic format should carry the electronic signature of the author. Absent an electronic signature, comments submitted electronically must be authenticated by submitting the signed original paper

document.

All comments submitted must identify the docket number, and regulatory identifier number (RIN).

z Docket Number EERE-2009-BT-TP0016 and RIN 1904-AB99

.

Comments may be submitted using any of the following methods: Pa g e 2 of 3 A pp liances and Commercial E q ui p ment Standards: Fluorescent Lam p Ballasts Test Proce...

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_ standards/residential/fluorescent

_ lam p_

...Building Technologies Program Home | EERE Home | U.S. Department of Energy

Webmaster | Web Site Policies | Security & Privacy | USA.gov

Content Last Updated: 03/19/2010 z Federal eRulemaking Portal: http://www.regulations.gov/ Follow the instructions for submitting

comments.

z E-mail:

FLB

- 2009

- TP

- 0016@ee.doe

Include docket number EERE-2009-
BT-TP-0016 and/or RIN 1904-AB99 in the subject line of the message.

z Postal Mail:

Brenda Edwards U.S. Department of Energy Building Technologies Program Mailstop EE-2J 1000 Independence Avenue, SW Washington, DC 20585-0121

Please include one signed original

paper copy.

z Hand Delivery or Courier:

Brenda Edwards U.S. Department of Energy Building Technologies Program 950 L'Enfant Plaza, 6th Floor Washington, DC 20024 Telephone: 202-586-2945 Please include one signed original

paper copy. Comments should clearly identify

docket number EERE-2009-BT-TP0016.

Contact Information

Linda Graves Project Manager

202-586-1851

Printable Version Pa g e 3 of 3 A pp liances and Commercial E q ui p ment Standards: Fluorescent Lam p Ballasts Test Proce...

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_ standards/residential/fluorescent

_ lam p_

...NEMA Test Procedure DRAFT Page 1 

## U.S. D EPARTMENT OF 

## E NERGY 

### Energy Conservation Program for Consumer Products and Certain Commercial and Industrial Equipment

Summary: The following document details a draft NEMA test procedure for the measurement of fluorescent lamp ballast efficiency. DO E summarizes this test procedure as an alternative method in the fluorescent lamp ballast active mode test procedure notice of proposed rulemaking (NOPR) in section III.E.2. DOE requests comment on this alternative test procedure as noted in section V.E.5 of the test procedure NOPR.

Problem Statement

As electronic ballasts gain performance and features, it becomes difficult to utilize aging industry standard test methods like the photometric based system measurement of BEF to fully and completely characterize the ballast electrical performance. Variations in lamp performance and errors inherent in the photometric measurement cloud the true performance of the ballast. As BEF is a system measurement, it is difficult to separate the performance contributed by the lamps and errors of the photometric measurement system from the ballast performance. A new metric is sought to accurately characterize performance levels of today’s high performance instant start and full cathode cutoff programmed start electronic ballasts.

Background, Task Force on Ballast Efficiency

The NEMA Task Force on Ballast Efficiency has worked to identify testing methods and test equipment characteristics necessary to accurately measure ballast performance. In NEMA Round Robin testing, sets of representative ballasts were operated on precision resistive loads and were measured by all the manufacturers and also by some independent laboratories. The goal was to arrive at an accurate and repeatable test methodology that could be used to evaluate ballast performance and provide a bridge to the generation of system operating parameters or a lamp equivalent transfer function without the use of lamps or photometric measurements.

Testing Issues-Resistive Loads

While good testing methodology was developed, it became clear that many sets of precision resistors would be needed to ensure the different ballast types were correctly operated with respect to the load characteristics. In the NEMA Round Robin testing, the resistors used approximated t he “normal light level” lamp load, about 760 ohms. In reality, the load characteristic varies from about 500 ohms for a “high light level” ballastNEMA Test Procedure DRAFT Page 2

to over 1200 ohms for a “low light level” ballast. In order to correctly test these 3 basic types, at least three sets of precision resistors would be needed. Trying to test the three different light level ballasts (L, N and H hereafter) on existing N level resistors would cause some ballasts to move off their designed operating point, and may not provide a true picture of the possible system performance. Some ballasts may react more or less favorably to the shift in load impedance, and may not present an accurate evaluation of the ballast’s true electrical performance. Also, some ballasts operate at a different point or output level when driving resistors compared to when driving an actual lamp load.

Simplified Test Plan Using Lamp Loads

To alleviate the issues associated with resistive loads, and to provide a simple path to determining ballast electrical efficiency, an alternative testing plan is presented here that will utilize lamp loads. The use of lamp loads will allow the ballast to operate at the correct output level for which the ballast was designed, as the lamp load is dynamic. Presently, the lamp load contributes 90 or more percent of the ballast input wattage. If the lamps are high in operating volts or power, this additional load will be reflected back as additional input wattage for the ballast and system, adversely affecting the BEF measurement that traditionally was the metric of ballast performance. Variations in lamp performance and error associated with the photometric measurement process affect the BEF numbers, as ballast factor divided by input wattage comprise the BEF metric.

The proposed ballast electrical efficiency test will utilize standard full wattage F32T8 lamps as the test load. Other lamp types may be used for comparative purposes, but only lamp types specified in CEE table shall be used to validate performance to CEE or NEMA Premium specification. The lamps used for this test should be nominal lamps per ANSI C78.81-2005 electrical requirements. The lamps should be seasoned for 12 hours and tested to be electrically stable. The lamps shall be mounted in a conventional strip fixture with lamps facing up for the measurements. The input wattage will only be a reference point for an output/input measurement, and will not be significant in itself. This allows effects of lamp operating point variation to be minimized, as the lamps will only act as an electrical load for the ballast.

The test is conducted using the highest input voltage the ballast is rated for, typically
277V for 120-277V rated ballasts.

Rated Input Voltage Test Voltage Comments
120V 120V +/

- 2%
277V 277V +/

- 2%
120

- 277V UNV 277V +/

- 2%
347V 347V +/

- 2%

347

- 480V UNV 480V +/

- 2%
480V 480V +/

- 2%

Note: Ballasts rated at other voltages are tested at the same tolerance level.NEMA Test Procedure DRAFT Page 3

The ballast input power and the sum of ballast output power would be simultaneously measured by a multi channel power analyzer. The wide bandwidth multi channel power analyzer should be capable of simultaneous measurements on multiple channels. The sum of the total output power would be divided by the input power and multiplied by 100, resulting in the percentage of electrical efficiency of the ballast under test.

This testing technique would allow relatively easy verification and validation of ballast electrical efficiency performance levels without the confounding factors of lamp and pho tometric measurement issues. This type of test could be utilized for all instant start ballasts and most programmed rapid start ballasts that do a full cathode cutoff once the lamp is operating. Ballasts designs that have continuously heated cathodes would not be tested by this method, as the cathode heating losses are not assignable.

This test method, when used in conjunction with the NEMA Premium MOU table of performance as shown on Appendix D, would determine if a ballast is qualified to be
listed as NEMA Premium.

Ballast Sampling Plan

Ballasts to be tested shall be selected from distribution stock. Four units shall be selected and used for the test. In case any of the test units fails to stabilize, an additional four piece sample can be drawn from stock and retested. Efficiency data is to be obtained from four tested units and the average of this data will be the reported value of Ballast Efficiency for purpose of NEMA Premium electrical performance
validation.

Test Plan Specifics

Lamps should be selected according to ANSI C78.81-2005 and be seasoned at least 12 hours prior to testing to ensure stable electrical characteristics. The lamps shall be full wattage F32T8. Amalgam lamps will not be considered here due to the long stabilization time required. The test process can be used with energy saving lamps; however, ballasts shall only be compared while operating similar lamp types. As an example, no ballast operated with an energy saving lamp will be directly compared to a ballast operated with a standard full wattage lamp.

For purpose of determination of compliance to NEMA Premium specification, only lamp types listed in CEE tables shall be used. In accordance with the NEMA Premium MOU Appendix D, Tables 1 and 2, the minimum electrical efficiency shall be as stated in the
Table.

Testing is to be conducted at room temperature, 25 C +/- 2 C, with minimal air movement. The lamps shall be protected from airflow that can disturb electrical operating characteristics, per ANSI C78.375.NEMA Test Procedure DRAFT Page 4 Lamp Fixture Set up

Lamps should be mounted in a standard strip fixture with lamps facing upward to minimize self-heating per standard ANSI bench conditions defined in ANSI C82.1-2004 and C78.81-2005. The ballast may be positioned on the bench, and the fixture shall be
el ectrically connected to the ballast case and to earth ground.

The ballast wire lengths shall be per manufacturer’s catalog specification. Lead wires shall not be shortened nor bundled or coiled to minimize stray capacitance and
inductive effects.

The test fixture shall be wired with standard 18 AWG solid conductor wire. All wires shall be loose in the fixture, not bundled or taped to the fixture metal. The wires shall represent wiring commonly used within a strip fixture. Connections to the ballast unde r test may be made by a terminal strip mounted on the side of the fixture or other
convenient means of connection.

Measurement Setup

The input and output power shall be measured by a wide bandwidth multi channel analyzer that is capable of simultaneous measurements of all channels. The analyzer shall have a traceable calibration, and be calibrated with the current transducers in place.

The ballast input current may be measured by the analyzer internal shunt or by an external current transducer that has been calibrated for use specifically with the power analyzer. The input voltage burden is negligible.

The ballast output current must be measured using non-invasive current transducer. The current transducer ratio must be set in the analyzer to match the transducer to the analyzer, and shall be calibrated at high frequency with the analyzer.

Note: The output from non-invasive current transducers is usually a low voltage signal; the actual current to voltage ratio to the power analyzer must consider the losses in addition to the transducer ratio. The full current to voltage ratio includes the voltage divider effect between the transducer and the power analyzer input. Assuming the use of a calibrated power analyzer and non-invasive transducer, the actual current to voltage ratio to use to fully correct the measurement is:

Iin: Current through transducer Vout: Voltage out of transducerNEMA Test Procedure DRAFT Page 5

Rin: Power Analyzer input impedance. Rs: Transducer output Impedance.

The lamp voltage is to be measured by use of flying individual leads to minimize stray capacitance of the setup. The use of coaxial cables or “zip cord” for the lamp voltage measurement is not recommended due to the excessive capacitance of such wiring.

The voltage connection of the analyzer to the lamps must be made after the current transducers, as this allows the voltage input burden to be as part of the total ballast output load.

For voltage connections to Programmed Rapid Start ballasts with full cathode cutoff, some residual heating voltage may be present even after the cathode heat cut off circuit has activated. The lamp voltage leads shall be tested in all combinations and the combination that produces the lowest lamp voltage per lamp shall be used for the test.
The lead combination shall be marked for future reference.

Methodology

The ballast shall be operated at its highest possible input voltage, typically 277V from an AC power source. The output of the power source shall route through the power analyzer to measure the ballast input conditions.

The lamps shall be run until a stable condition exists. Stability can be determined per methodology defined in ANSI C78.375-1997. A maximum of 1 hour of ballast and lamp system operation is permitted. If stability is not attained within the allowed one hour of system operation time, the lamps and /or ballast shall be replaced with additional samples of the same type and the test re-initiated.NEMA Test Procedure DRAFT Page 6 Test Procedure

1. Connect ballast and seasoned full wattage lamps to power analyzer and power source per the wiring diagram. Refer to Figure 1 for Instant Start ballasts and to Figure 2 for Programmed Rapid Start ballasts with full cathode cutoff. The lamps shall be in strip fixtures, positioned horizontally, with lamps on the topside.

2. Energize the ballast at the highest rated input voltage; check the analyzer for proper polarities and positive wattages.

3. Allow the ballast and lamps to warm up for at least 15 minutes to stabilize. The warm-up period can extend to an hour if needed for stability, but the final
measurement must be taken within the hour.

4. Record the input wattage and the sum of the output wattages measured. Other characteristics such as lamp currents and voltages may be recorded to ensure lamp performance is within the normal operating range.

5. Divide the sum of the output wattage by the input wattage and multiply the result by 100 to get the percentage efficiency of the ballast under test.

((Pout1+Pout2)/Pinput)*100 = Ballast Efficiency

Exceptions

Non-Dimming ballasts that have continuous cathode heating shall not be tested by this
methodNEMA Test Procedure DRAFT Page 7 Schematic of Test Setup for 2 Lamp Ballasts



# IS
Ballast R

ed

Bl

ue Bl

u e Bl

Wh
ite Current
transducer “Common” voltage measurement point Lamp 1

Lamp 2 Voltage measurement points: after
Current Transducer

AC Input
Power
from Analyzer



# PRS

Ballast Bl

Wh
ite AC Input
Power from Analyzer Lamp 1

Lamp 2 Current
Tra nsducer “Common” voltage

measurement points: select
for Lowest Lamp Voltage Lamp voltage measurement points:
test all combinations and select for Lowest Lamp Voltage. Fig. 1

Fig. 2