General Dimming Ballast Training

Bart Manguno Dan Perkins

A little about Lutron...

1961: Founded by Joel & Ruth Spira 1961: 1st solid state dimmer (Rotary) 1968: 1st fluorescent dimmer 1971: 1st electronic dimming ballast 1991: ISO 9001 certified 1992: Automatic shading system (Serena) 1996: 1st RF controlled dimming system 2004 Shipped 1st EcoSystem Job Today: Global organization & world leader in lighting controls

Innovation and Quality

Annual growth average over 20% Reinvest 10% of sales revenue into R&D annually Over 250 U.S. Patents One of the first 20 U.S. companies to gain ISO 9001 Certification Over 12,000 Products from single circuit dimmer to control systems which can handle millions of lighting circuits 100% EOL testing Mass customization 24/7 technical support

Global Organization
Corporate Headquarters: Coopersburg, PA Manufacturing: Pennsylvania, Virginia; St Kitts; Puerto Rico; London, Shanghai; Mexico Warehouse / Distribution: Pennsylvania; London Sales Offices:

North America
Comm Spec Teams in NY, LA, LV, Chicago, Dallas & Pacific NW Direct sales teams in Canada, Mexico, Latin America, Pacific NW Manufacturing Reps throughout North America

International
London Madrid Barcelona Paris Berlin Dubai Singapore Shanghai Beijing Sao Paolo Tokyo Hong Kong

Our Vision
To help partners meet demands of lighting todays buildings by:
Influencing luminaire design based on watt hours per sq ft (not just lumens per watt and watts per sq. ft.)
Specifying intelligent, digital, addressable fixtures with maximum controllability to: Measure watt hours per sq. ft. Report status, current power consumption Load shed during peak demands

Why Dim? Cost to generate a watt is 4 - 22 times more expensive than the cost to save a watt using dimmers (NegaWatt). *
* Source: Building Dimmers vs. Building Power Plants: An Economic Analysis, Mar 2009

Technical Overview

Lets Get Technical

Fluorescent Dimming Overview

Ballast supplies the lamp with high voltage at both ends Phosphor coating reacts with UV photons released by the plasma arc stream and converts to visible light
Excitation of Phosphor Coating (Visible Light)

UV Light Emission

Arc Stream

Rapid Start vs. Instant Start

Rapid Start sockets required for programmed start

allow current flow to heat the filament

required for dimming applications Instant start sockets only allow current to flow to the arc

Not for dimming

Wiring Ballasts to Lamp Holders

All dimming ballasts require Rapid Start sockets All Lutron multi-lamp ballasts wire in parallel
Single Lamp Models

Correct
Three Lamp Eco-10 & Hi-lume only

Wrong
All Two Lamp Models Three Lamp EcoSystem & Hi-lume 3D only

Socket Lead Lengths

Linear Lamps T8 & T5

All lamp leads Maximum 7 feet (2.1m)

Compact lamps - T4 Compact & T5 Twin tube

All lamp leads Maximum 3 feet (0.9m)

Using High Quality Sockets

Good lamp pin connections is essential for dimming Using correct lamp holders is the key to reliable performance Lutron recommends using lamp holders that meet European IEC Specification 60400: superior quality more reliable connections Some brands of IEC compliant sockets domestically available are: -A.A.G. Stucchi -Vossloh Schwabe -BJB

Ballast Mounting
Lutron ballasts dissipate a small amount of heat and must be mounted to a flat metal portion of the fixture This metal will transfer the heat more effectively if it is exposed to the exterior of the fixture. Fixtures should be thermally tested with the ballast to ensure that they are thermally compatible. Ballasts must be mechanically secured to the fixture so that the ballast and fixture are electrically connected or grounded. It is a UL requirement that all parts of a light fixture be grounded. Lutron recommends using paint piercing hardware such as star washers or press-nuts to mount the ballasts.

Good
Poor Poor Poor
Note: Double sided tape is unacceptable for mounting ballasts.

Lamp to Fixture Separation

Lamp Wall Ground Plane
All fluorescent lamps capacitively leak current through the walls of the lamp This phenomena is expected and compensated for in the ballast design When dimming a lamp, it is more critical to keep capacitive leakage within a certain range This range can be controlled by establishing minimum and maximum separation dimensions of the lamp to the ground plane (refer to ANSI C78.1&2)

Min-Max Distance of Lamp Wall from Ground Plane

Lamp Type

1% Ballasts

10% Ballasts

T8 Linear T5 Linear T5 Twin Tube

1/8 - 3/4 1/16 1/2 1/8 1/2

1/8 - 3/4 1/16 1/2 1/16 1/2

Note: It is unacceptable for the lamps to come into contact with metal parts of the fixture. (ANSI C82.11)

Ground Plane Clearance

Lamp Seasoning
Consult lamp manufacturers for their recommendations on lamp seasoning prior to dimming National Electrical Manufacturers Association (NEMA) recommends 12 hour lamp seasoning

Control Types
Two Wire

Three Wire
0-10 volt Digital Addressable Lighting Interface (DALI)

DALI Ballast

EcoSystem

Maximum controllability in an easy to retrofit topology which,can use existing Class 1 wiring
All controls are Class 2 & home run to nearest EcoSystem fixture Polarity free

System programming is simple (uses PDA w/infra-red connection) Coordinating job lay out requires more application information up front

EcoSystem Project Checklist

Use the EcoSystem project checklist in your packets through all phases (quotes to shipping)

Provides a checklist to ensure you collect all of the necessary information to manufacture a fixture with EcoSystem ballasts Applies to Quotes, Order Entry, Production, Shipping, Post Sales
EcoSystem projects are cost effective and efficient if you gather the correct information from the start of the project USE THE ECOSYSTEM CHECKLIST

EcoSystem Components

Example: Multi-Fixture Room

Traditional systems have upstream controls that make decisions.
Digital Ballast Loop

Bus Supply Controller

Daylight Sensor/ IR Receiver

Zone 1

Zone 2 Zone 3

Example: Multi-Fixture Room

Class 2 Wallstation

Wallstations
Wire to any ballast after install Front/Back of Room Four scenes Group

Zone 1

Zone 2

EcoSystem Ballast Connections

EcoSystem Wiring Practices

Line Voltage
Leaded ballasts (-L) supplied with #18 AWG leads
Input (Power) connections (18 long) Switched Hot, Dimmed Hot, Neutral Output Connections (36 long) - lamp socket connections Bus wires (18 long) Sensor wires not supplied

Terminal ballasts (no leads)

Input and lamp socket connections accommodate 18-16AWG solid Sensor terminals accommodate 22 AWG Solid

EcoSystem Wiring Practices

Class 2 Control wiring, Low Voltage <30V
May be run without conduit Plenum cable available Must be separated from class 1 wires by one of the following:
0.25 separation Separated by a physical barrier Or be rated for 600v

Note: E1/E2 may be run using existing Class1 wiring,

Lutron App. Note 142

Class 2 Cable Sourcing

Options for obtaining EcoSystem wire: 1. Purchase 1000 ft spools direct from Lutron 2. Source Lutron spec. wire direct from a wire manufacturer 3. Purchase pre-cut and pre-stripped sensor and bus whips from a 3rd party supplier

Atronics Incorporated Contract Manufacturing & Cable Assembly

Tooled to source and build cost effective class II cabling for EcoSystem fixtures precut and pre-stripped to your specifications. Has direct access to Lutron specified cable for EcoSystem sensors and digital bus and will work directly with OEMs to create unique part numbering which fits into the OEMs specific part numbering guidelines. For contact information and pricing, refer to hand out.

EcoSystem Wiring Example

Mingling Class 1 & Class 2 in Pendants

Power Drop
(5 Conductor)
Black = Hot White = Neutral Bare = Ground Purple = E1 Purple/White = E2

Sensor Drop
(5 Conductor)
Red = +20v Black = Common Blue = Occ Sensor White = Wall Control / IR Yellow = Daylight (Optional)

Hi-lume LED driver

Constant current driver for 25W and either 2.1 or 1.4Amps Dims from 100% to 1% of total light output Compatible with EcoSystem and 3-wire controls Universal Voltage (120V and 277V) UL Recognized (UL 8750) LED driver

Fixture Qualification Program

Hi-lume LED driver is sold through qualified OEMs Product testing from the OEM and Lutron ensures compatibility between products List is posted at: www.lutron.com/hilumeled/fixtures

Ballast Warranty
Off the shelf ballast is warranted for 3 years
Warranty is extended to 5 years upon commissioning

Tech Support can issue RGAs and warranty replacements

Getting Assistance

Technical Support (800) 523-9466

Refer customers & contractors for RGAs and initial troubleshooting

Applications Support
Dan Perkins (OEM Tech Apps. 610 282-7569)

Sales Support
Bart Manguno (OEM sales 610 282-7809) Tom Murphy (OEM Sales 610 282-7592) Jim Yorgey (Tech. Sales 610 282-7332)