Troubleshooting & Maintenance for HID Lighting · 2020. 7. 14. · Universal Lighting Technologies...

Universal Lighting Technologies is a subsidiary of Panasonic Lighting Americas,a member of the Panasonic Corporation Eco Solutions Company

High Intensity Discharge(HID) is a broad term used to describe any lighting system using a gaseous discharge arc lamp in which the gas-filled arc tubeoperates at several times normal atmospheric pressure compared to the near vacuum conditions in fluorescent lamps. The various types of HID lamps are categorized and named by the type of gas contained within the arc tube.

The electrical arc produced between the two main electrodes of an HID lamp is much like a runaway short circuit which can besustained indefinitely. Once sufficient voltage is present, the gases within the arc tube are “ionized” to where they will conduct thearc current. Arc formation is not an immediate process. It can take several seconds for the arc to be established, and severalminutes until full light output can be reached.

HID lamps are negative impedance devices. This means that unless controlled, the current would continue to increase, causingthe lamp to fail almost instantly after starting. For this reason, a ballast, which is a current-limiting device, must be used with every HID lamp. The ballast serves three functions. It provides the proper starting voltage to establish the arc. Second, it supplies the proper voltage to operate the lamp. Third, the ballast limits the lamp current to a level prescribed by the lamp manufacturer for the particular type of lamp being used. Ballasts must always be matched to the particular lamp type, wattage, and line voltage being used. Never use a ballast for any lamp, installation or purpose other than that for which it has been specifically designed.

The ionization voltage of all HID lamps increases greatly when the lamp is hot. If power to the lamp is interrupted, the lamp must be allowed to cool for a time, usually several minutes, before the arc can be reestablished and normal operation resumed. For this reason, some ballasts are available with a tap to operate a standby, or auxiliary, incandescent lamp through an appropriate interface device. The 120-volt lead on dual-,tri-, and multi-voltage ballasts can be used as a tap for standby lighting when the ballast issupplied by a higher line voltage. For some ballast-lamp combinations, an instant restrike starter is available.

Suggestions for HID Fixture MaintenanceProper maintenance of any lighting system is essential to maintain levels of illumination necessary for productivity,merchandising, visual comfort, safety, and security. If an individual component fails and is allowed to remain in the lightingsystem, costly damage to other components can result. Major repairs can often be avoided by simple maintenanceprocedures and timely attention to small problems, such as replacing burned-out lamps.

Preventing a problem from occurring is more desirable and economical than fixing it later. A scheduled program of preventive main-tenance can save money while maintaining productivity and safety. By using the following maintenance strategies, the ballast will have a longer, more trouble-free life. There are many lighting maintenance contractors and electrical contractors who can economi-cally perform a scheduled maintenance program.

Group RelampingLamps should be replaced as a group at scheduled periodic intervals, based on rated life, minimum acceptable lighting levels, and system operation cost. Your lamp supplier has additional information available regarding lamp maintenance procedures.

CleaningLamps, reflectors, and lenses should be cleaned periodically. Be sure to follow the recommendations of the fixture and/or reflector manufacturer.

InspectionIn addition, to obtain normal ballast life and maximum efficiency from an HID lighting installation, fixtures should periodically be inspected for:

• Lamps cycling on and off • Heavy lamp discoloration • Dim lamps • Slow-starting lamps • Inoperative lamps • Dust and dirt

Troubleshooting & Maintenance for HID Lighting


The significance and correction of these conditions can vary with the type of lamp and ballast used; these are covered in greater detail in this guide.

Lamps should be checked to be sure the proper lamp type is being used, according to the information on the label of the installed ballast. Many lamp types currently offered, such as metal halide and high pressure sodium lamps, are physically interchangeable,but not electrically interchangeable.

Line voltage should be checked at the fixture and compared with the ballast rating to be sure it is within the prescribed limits.(See Appendix E.)A high pressure sodium lamp cycling on and off usually indicates the lamp has reached the end of its normal life. (See Appendix B.)

Lamps cycling on and off with an encased & potted ballast, or other ballast which contains thermal protection, may be a warning that the ballast is operating at too high a temperature, causing the automatic resetting thermal protector to deactivate the ballast when the temperature limit is exceeded. (See Appendix G.)

Make certain that the polarity is correct. (See Appendix E.)

Be sure the fixture, ballast, capacitor and starter are properly grounded. (See Appendix E.)

Safety FirstBallast, capacitor and starter replacement, as well as lighting maintenance, presents the possibility of exposure to potentiallyhazardous voltages and should be performed only by qualified personnel. All installation, inspection and maintenance should be performed only with the entire circuit power to the fixture or equipment turned off.

All ballasts, components and fixtures must be installed and operated in compliance with the National Electrical Code, requirements of Underwriters Laboratories, Inc., and all applicable codes and regulations. This includes, but is not limited to, proper grounding of ballasts, components and fixtures as well as prescribed branch and total circuit protection.

TroubleshootingThis concise guide provides a logical sequence and procedures for troubleshooting and correcting the most commonly encounteredproblems in a typical HID lighting system. There are many specialized ballasts, lamps, fixtures, and lighting controls which are notspecifically addressed. The troubleshooter should always check for special conditions which might exist in an installation, creatingan exception to the rules or a potential safety hazard.

Protect the BallastA ballast, like any electrical device, generates heat. To ensure maximum ballast life, it is imperative that operating temperatures be kept low. Burned-out or failing lamps, or high temperatures in or around the fixture, can cause the ballast to overheat, resulting in premature failure. For more information regarding heat’s effect on ballast life, in addition to recommendations for maximizing ballast life and performance, consult Universal Lighting Technologies’ catalogs.

For Additional AssistanceIf additional troubleshooting assistance is required, or you have any questions regarding your lighting system, we’re ready to help! Call Universal Lighting Technologies’ Technical Engineering Service™ Department at 1-800-BALLAST.

Universal Lighting Technologies26 Century Blvd., Suite 500

Nashville, TN 37214-3683

P: (615) 316-5100

E: [email protected]


Troubleshooting Maintenance HID Lighting



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Is there power to the fixture? NO Correct external cause and check for normal operationYES

Are in-line fuses or other devices such as photocells, automatic shut-off starters or

sensors at fault or causing the problem?

YESReplace the faulty components, or reset shut-off devices, and check for normal operation.

NO

Are abnormal lamp or socket conditions at fault? (See

Appendix A)YES

Correct the abnormal conditions, replace components as needed and check for normal

operation.

NOHas the lamp failed under normal conditions? (See

Appendix B)YES Replace the failed lamp and check for normal operation.

NOAre the lamp, ballast, capacitor

and starter (if applicable) compatible? (See Appencix

C)

NOReplace the incorrect

component (s) and check for normal operation.

YESAre the ballast and starter mounted too far from the lamp? (See Appendix C)

YES Correct to proper distance or install a long-distance starter.

NO

Is the Fixture wired Correctly? (See Appendix D) NO

Correct and check for normal operation.

YESAre the line voltage and tap connections correct? (See

Appendix E)NO

Correct the supply voltage to within specified tolerance or

correct tap connection.

YES

Is the capacitor faulty? (See Appendix F) YES

Replace the faulty capacitor and check for normal operation.

NOAre the ballast and starter operationg properly? (See

Appendix D)NO Replace the faulty component and check for normal operation.

Universal Lighting Technologies, Inc.

26 Century Blvd., Suite 500

Nashville, TN 37214-3683(615) 316-5100http://www.universalballast.comE-mail: [email protected]

CHART 1Lamp Is Inoperative





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CHART 2

Is the lamp compatible with the system? NO Replace with the correct lamp.

YES

Is the lamp operating in correct position? (See Appendix A) NO

Replace the lamp with an appropriate lamp for the

operating position or change operating position.

YESIs the outer bulb cracked?

(See Appendix A) YESReplace the lamp and check for

normal operation.

NOAre there signs of lamp

overwattage or overcurrent operation? (See Appendix A)

NO Replace the lamp and check for normal operation.

YES

Are the Components compatible? (See Appendix C) NO

Replace the incorrect component(s) and check for

normal operation.


Appendix E)NO



YESIs the capacitor shorted? (See

Appendix F) YESReplace the faulty capacitor and

check for normal operation.

NO

Is the ballast operating properly? (See Appendix D) NO

Replace the faulty ballast and check for normal operation.

NO

Are operating periods shorter than rated? (See Appendix B) YES

Reassess hours per start and adjust estimate of lamp life

accordingly.

Universal Lighting Technologies, Inc.26 Century Blvd., Suite 500


(615) 316-5100

http://www.universalballast.com

E-mail: [email protected]

Very Short Lamp Life





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CHART 3

Has the lamp's light output depreciated normally? (See

Appendix B)YES Replace the lamp and check for normal operation.

NO

Are the components compatible? (See Appendix C) NO

Replace the incorrect component(s) and check for

normal operation.


Appendix E)NO



YES

Is the capacitor faulty? (See Appendix F) YES

Replace the faulty capacitor and check for normal operation.

NOIs the ballast operating

properly? (See Appendix D) NOReplace faulty ballast and


Universal Lighting Technologies, Inc.26 Century Blvd., Suite 500


(615) 316-5100

http://www.universalballast.com

E-mail: [email protected]

Low Lamp Light Output





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CHART 4

Has the lamp reached the normal end of its life? (See

Appendix B)YES Replace the lamp and check for normal operation.

NOAre the components

compatible? (See Appendix C)

NOReplace the incorrect

component(s) and check for normal operation.

YESAre abnormal socked or wiring

conditions at fault? (See Appendix A)

YES Correct abnormal condition(s) and check for normal operation.

NO

Is the line voltage correct? (See Appendix E) NO

Correct the supply voltage to within specified tolerance and check for normal operation.

YESAre ambient condition(s)

causing the cycling? (See Appendix G)

YES Correct abnormal condition(s) and check for normal operation.

NOIs the ballast operating

properly? (See Appendix D) NOReplace faulty ballast and


Universal Lighting Technologies, Inc.26 Century Blvd., Suite 500Nashville, TN 37214-3683(615) 316-5100http://www.universalballast.comE-mail: [email protected]

Lamp Cycling On and Off


Appendix A: Possible Lamp& Socket Problems

Lamp Base to Socket ContactGood electrical contact between the lamp base and the socket is essential. Check to see if the lamp is loose in the socket or if the base is distorted so that the lamp will not seat properly.

Faulty Socket or WiringCheck socket for loose contacts, poor connections, or broken wiring.

Pulse-Rated SocketHigh pressure sodium and low-wattage metal halide lamps require a starter that provides a high-voltage pulse to start the lamp.The socket must be capable of withstanding the pulse without arcing. A pulse-rated socket is required.

Lamp Operation PositionSome metal halide lamps are restricted to an optimum operating position. For example, base-up to horizontal are so identified inthe lamp etch. The proper lamp must be used for the given operating position. Other metal halide lamps, which are designed for horizontal operation only, have a special position-oriented base which must be used with a matching socket to assure proper arc tube orientation. Otherwise, the lamp will produce low light output and fail early.

Lamp Damage Due to Handling or ShippingDamage to the outer bulb from handling or shipping may cause a crack in the glass, broken tubes or wires, or loose parts in the lamp. Air entering the bulb will oxidize the metal parts and result in short lamp life.

High pressure sodium lamps contain a getter-the dark material in the outer bulb, near the base. The getter absorbs residual oxygen from the lamp-making process. If air has entered the bulb, the getter will be used up. It will appear white or be gone.

Lamp Damage Due to Overwattage or Overcurrent OperationOverwattage or overcurrent operation will result in short lamp life. Signs include a swollen, bulged or blackened arc tube, melted wires or ribbons inside the lamp, and a discolored outer bulb.

HID Lighting



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Appendix B: Lamp Performance Data

Rated Average LifeRated average lamp life is based on tests of large groups of lamps under specified conditions.All lamps do not last until rated average life. They fail in accordance with a mortality curve.Note that 35%-50% of lamps in a large group can be expected to fail before the ratedaverage life value is reached, and that 50%-65% last longer than the rated average life.

Group RelampingThe interval between group relampings is determined by theminimum acceptable light level for the application and economics.The light level will be determined by the lumen maintenance of thelamp and dirt conditions, and the economics by the mortality curve,lamp and labor costs.

Your lamp suppliers have information for determining the best time schedule for your conditions.

Restarting TimeIn the event of a power interruption, HID lamps require time to cool down before they will restart.

Approximate Restarting TimeMercury and metal halide: 4 to 10 minutesHigh pressure sodium: 1 minute

In tight or enclosed fixtures, mercury and metal halide lamps could take up to 20 minutes to cool down.

Normal End-of-LifeMercury Lamps

Normal end-of-life is indicated by blackening of the ends of the arc tube, deterioration ofthe electrodes and/or intermittent starting. Light output will generally be low, but present.

Metal Halide Lamps

Normal end-of-life is caused by sodium loss from the arc tube. The lamp may be hard to start. Color may be blue or pink,depending on operating position. Light output will be low.

High Pressure Sodium Lamps

Normal end-of-life is usually indicated by the lamp cycling on and off. As the lamp accumulated burning hours, its operatingvoltage increases, eventually becoming higher than the voltage supplied by the ballast. The lamp extinguishes and cools.The ballast restrikes the arc. The lamp voltage increases again and the lamp extinguishes. This process typically blackensthe end of the arc tube.

Lamp Lumen Maintenance

The light output of HID lamps depreciates as the lamps accumulateburning hours. The degree depends on the lamp type.

HID Lighting



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Approximate Lumen Maintenance

Percent of Rated Average Life

Per

cent

Initi

al L

umen

s

0 10 20 30 40 50 60 70 80 90 100

100

80

60

40

20

0

High Pressure Sodium Lamps Metal Halide and Mercury Lamps

100

90

80

70

60

50

40

30

20

10

00 20 40 60 80 100 120 140 160

Percent of Average Life

Per

cent

Sur

vive

d

Mortality Curve


Appendix C: Compatibility

Incompatible ComponentsThese components could include an improper lamp, ballast, capacitor or starter (if applicable). All components must be compatible. Check the lamp description and the labels on the ballast, capacitor and starter.

Remember that although mercury lamps operate at the same wattage as metal halide, a mercury-rated ballast will not start and operate a metal halide lamp due to the differences in required starting voltage.

In addition, operation of metal halide or mercury lamps on high pressure sodium ballasts will result in over-wattage operation,causing early lamp failure.

Ballast and/or Starter LocationThe ballast and/or starter may be located too far from the lamp. Too great a distance can result in an excessive voltage drop inthe wiring or excessive capacitance between the leads, which will reduce the amplitude of the starting pulse below that required to ionize the gas. Check the labels on the ballast and the starter to determine the maximum permissible distance. Remember that wire size and type of conduit and wire used will affect the starting distance. See Universal Lighting Technologies’ catalog for additional information.

Auto Shut-Off StartersIn the event of lamp failure, a standard starter will continue trying to start the lamp. This may reduce the life of the starter andthe ballast. To prevent a starter-induced ballast failure, Universal Lighting Technologies offers a line of automatic shut-off starters.When the lamp becomes inoperative, the Auto Shut-Off will pulse for approximately 10-12 minutes and then deactivate if alamp arc current cannot be initiated. To reset the starter, simply interrupt the power to the ballast momentarily. For this reason,Auto Shut-Off starters are not recommended for use on unswitched circuits.

Low TemperatureThe voltage required to start HID lamps increases as the temperature decreases. Ballasts are rated for starting down to a specified temperature. Check the ballast label.

HID Lighting



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Appendix D: Ballast and Starter Test

Improper Fixture WiringCheck the wiring diagram on the ballast label.

Ballast TestBallast test for all mercury and 175- and higher-wattage

Metal halide fixtures (which do not require a starter):

1. Install a known good lamp.

2. If the lamp lights normally, you have corrected the cause of the problem.

3. If the lamp does not light, and all previous checks do not reveal any circuit problem, replace the ballast.Normal operation should resume. To ensure proper performance, also replace the capacitor.

Ballast and Starter TestBallast and starter tests for high pressure sodium fixtures:

1. Install a known good lamp.

2. If the lamp lights normally, you have just corrected the cause of the problem.

3. If the lamp does not light, disconnect the starter and install the specified TEST LAMP.

4. If the TEST LAMP lights, the ballast is good and the starter is inoperative. Replace the starter.

5. If the TEST LAMP does not light, the ballast is inoperative. Replace the ballast. To ensure proper performance,also replace the capacitor and starter.

System

35-watt to 150-watt (55-volt, S55)

150-watt (100-volt, S56) to 1,000-watt

Lamp

120-volt incandescent lamp of equal or higher wattage

Mercury lamp of comparable wattage

Test Lamps for Use with HPS Ballasts Only

HID Lighting



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Appendix E: Line Voltage

Operating Line Voltage LimitsTo receive the full benefits of rated lamp light output and to prolong ballast life, it is essential that the voltage supplied to aninstallation be maintained within the prescribed limits.

PolarityPolarity refers to the proper connection of ballast lead wires to line wires. To aid in correct installation, Universal LightingTechnologies ballast leads are color-coded for ease of identification. The white or yellow ballast lead is to be connected tothe neutral or common (grounded), and the black ballast lead always to the line, phase a,b, or c on a 3-phase, 4-wire system(typically 120 or 277 volts). When connected to the 3-phase ungrounded system (typically 208 or 480 volts), the black goesto one phase and the white or yellow lead goes to the second line phase-i.e., a-b, b-c, or c-a.

GroundingAll ballasts and capacitors or starters in metallic casings must always be grounded. Ballasts and components may begrounded to the fixture or otherwise connected to the ground. It is hazardous and possibly fatal for a human to makecontact with an ungrounded fixture, ballast or other electrical component while it is in operation.

Low voltage has no damaging effect on the ballast. It could, however, have an adverse effect on lamp performance andstarting dependabilty.

Subjecting a ballast to excessive voltage for an extended period of time results in the deterioration of the coil insulation.The insulation breakdown will cause early ballast failure.

Ballast Type

Reactor (R) or high reactance autotransformer (HX)

Constant wattage autotransformer (CWA) or ISO Reg

Limits

± 5%

± 10%

HID Lighting



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Appendix F: Capacitor Test

Checking the Capacitor1. Disconnect the capacitor.

2. Discharge the capacitor.

3. Use an ohmmeter on the highest scale.

4. If meter reads low resistance initially and increases, the capacitor is GOOD.

5. If meter reads low resistance initially and does not change, it is SHORTED and must be replaced.

6. If meter reads high resistance initially and does not change, it is OPEN and must be replaced.

Be sure to check for and correct abnormal conditions such as high ambient temperature, incompatibility, etc. – which may have caused or contributed to capacitor failure, or caused the capacitor’s internal protector to activate.

Faulty Capacitor

HID Lighting



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Capacitor Condition Ballast Type Result

Shortened High ReactanceHigh line current. May open circuit breaker or burn out the primary coil of the ballast. Capacitor’s internal protector may function,resulting in open capacitor and normal power factor operation.

Shortened CWA Metal Halide and MercuryHigh lamp current. May open circuit breaker or burn outthe primary coil of the ballast. May shorten lamp life.

Shortened CWA HPS Low lamp current. Low light output. No ballast damage.

ShortenedCWA Dual (Parallel) Capacitor(one shorted)

See above results, depending on ballast type used.

Open High ReactanceLose power factor correction. High line current. May opencircuit breaker. May burn out the primary coil of the ballast.

Open CWA Single Capacitor Lamp will not light.

OpenCWA Dual (Parallel) Capacitor(one open)

Low lamp current. Low light output.

Open CWA Dual Capacitor (both open) Lamp will not light.


Appendix G: Ballast Overheating

A ballast, like any other electrical device, generates heat during normal operation. Planning for maximum heat dissipation with proper fixture design, installation planning and ballast selection will minimize the possibility of a heat-related problem. Excessive temperature will have an adverse effect on ballast life.

Normal Temperature LimitsEncased & PottedMaximum case temperature: 90°C

Postline BallastsMaximum case temperature: 90°C

Weatherproof BallastsMaximum case temperature: 90°C

Core & Coil BallastsInsulation: H 180°CMaximum coil temperature: 165°C(measured by change of resistance method)

Potted Core & Coil BallastsInsulation: Class 180Maximum coil temperature: 165°C(measured by change of resistance method)

Indoor EncasedMaximum case temperature: 90°C

Encased & Potted ballasts are equipped with an automatic-resetting thermal protection device as a built-in standard internal feature.

The resetting thermal protector functions as a thermostat which will open and temporarily deactivate the ballast when it exceedsthe permissible temperature. The ballast will continue to cycle until the cause of overheating is eliminated. If the ballast if defective,it must be replaced. If the cause is external, the ballast will resume normal operation after abnormal conditions are eliminated.Possible external causes include insulation around the fixture or poor air circulation around the fixture.

Whenever a ballast with thermal protection is used, it is imperative that the fixture/ballast-lamp combination be heat-tested under actual or simulated installation conditions to ensure that the ballast will not cycle.

Other ballast types may be available with thermal protection as an option. If required, call Universal Lighting Technologies’ Technical Engineering Services at 1-800-762-4837 for availability and ordering information.

Even when a ballast is protected against excessive operating temperature, it is still subject to the normal parameters for ballastlife. In the proper application and for normal ballast life, maximum coil temperature of the ballast should not exceed the rating ofthe insulation system. A temperature rise of 10°C can result in a 50% reduction in ballast life. This elevated temperature couldoccur without tripping the thermal protector.

Note: Special attention should be given to remote mounting of indoor encased ballasts.They should be mounted at least 12” apart to prevent over-heating.

HID Lighting



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Troubleshooting and Maintenance for HID LightingCH_HID_Maintenance Chart 1CH_HID_Maintenance Chart 2CH_HID_Maintenance Chart 3CH_HID_Maintenance Chart 4CH_HID_Appendix ACH_HID_Appendix BCH_HID_Appendix CCH_HID_Appendix DCH_HID_Appendix ECH_HID_Appendix FCH_HID_Appendix G

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