So a converted luminaire that works with new lamps in the conversion shop might fail to start after the lamps have aged a relatively short time in the field. An operating voltage test should also be performed to ensure the luminaire is not overdriving the lamp. As you can see, the time, effort, and cost involved in performing the most complete conversion possible can be quite significant, particularly when you consider that the results will not match the performance and life of a new HPS luminaire. Those who convert their fixtures in a shop or in some fashion of an assembly line operation often do not consider the full cost of the kit conversion until the cost of other items are added in. These items could include fixture cartons, cleaning materials, component replacement parts, test equipment, storage, manufacturing facility cost, and product liability responsibilities.
Product liability is a major concern, often overlooked.
Once a luminaire is converted or remanufactured by the user, product liability becomes the sole responsibility of the user. Luminaires that have undergone kit conversions and are later inspected in the field often show the absence of complete quality control standards. For example, roadway luminaire manufacturers establish and maintain fastener quality and installation torque specifications that are used in the manufacture of all new luminaires. Failure to maintain these specifications during luminaire conversion could result in component fastener failure. The worst case failure condition could be a ballast that might fall from a luminaire, causing bodily injury or proper damage.