The Next Generation of Electronic Lighting Systems:
Smaller, Smarter and Greater Energy Savings

By Craig DiLouie, Lighting Controls Association

Published 2003

History is Made: Electronic Ballasts Dominate in 2001-2002

In 2001, a small moment in history: The electronic ballast passed the magnetic ballast in total unit sales volume, the culmination of a trend that had been years in the making. Electronic ballasts, in fact, had already surpassed magnetic in dollar sales volume in 1995. According to the U.S. Economic Census, in 2002 electronic ballasts represented 57 percent of all ballasts shipped in the United States, and 69 percent of dollar volume. In the lines in Figures 1 and 2, we can read the classic story of a technology reaching maturity. Considering that electronic ballasts comprised only 14 percent of units shipped and 34 percent of dollar volume in 1992, the rapid ascendance of this technology is quite remarkable. Going back a little further, to 1986, electronic ballasts barely even registered on the radar, representing just 0.6 percent of units shipped -- which, incidentally, is about half of where linear dimmable electronic ballasts are now.

Figure 1. U.S. Fluorescent Ballast Shipments in Thousands of Units. Source: U.S. Census Bureau, 2002 Economic Census.

Figure 2. Value of U.S. Fluorescent Ballast Shipments in Thousands of Dollars. Source: U.S. Census Bureau, 2002 Economic Census.

Electronic ballasts poised to control market

Two new regulatory developments will clinch the dominance of electronic ballasts and make them the new standard over time, a standard that the industry is already beginning to beat with even better technology.

First is a U.S. Department of Energy (DOE) ruling that stipulates new ballast efficacy standards to begin phased adoption in 2005. The first part takes effect on April 1, 2005, requiring that all ballasts manufactured in the United States for operation of F40T12 and F96T12 lamps (and sold after July 1, 2005) must meet these new efficacy requirements, as shown in the below table. As of April 1, 2006, lighting fixture manufacturers will no longer be able to integrate ballasts that do not meet these new efficacy standards into new fixtures.

In most cases, only electronic ballasts will comply, although energy-efficient magnetic ballasts will continue to be manufactured for F96T12HO lamps rated for -20 F for all applications with the exception of outdoor signs.

Exceptions to the rule also include ballasts that have a power factor less than 0.90 that are designed/labeled for residential use and ballasts dimmable to 50% or less. T8 lamps are not covered by the rule, as there are several applications, such as electronic sensitive areas, where electronic ballasts would not be used.

Ballasts meeting the old ballast efficacy standards will continue to be manufactured for replacement use, limited to short leads and quantities of 10 or less. They will be marked, FOR REPLACEMENT USE ONLY. The ballasts will be available until July 1, 2010.

The second regulatory development is another DOE ruling implementing a provision of the Energy Policy Act of 1992, which stipulates that as of July 15, 2004, all states in the Union must certify that they have energy codes in place that are at least as stringent as ASHRAE/IES Standard 90.1-1999, or justify why they cannot comply. As of September 2002, 18 states already have energy codes that meet or exceed the requirements of Standard 90.1-1999. The lighting requirements of Standard 90.1-1999 are stringent enough (1.3W/sq.ft. power allowance for open office spaces, for example) to essentially require the adoption of electronic ballasts for new construction and renovations.

The adoption of the ASHRAE Standard will impact the electronic ballast market in another way -- through growth of use of occupancy sensors and other automatic controls that result in frequent switching of fluorescent lamps. As a result, programmed-start ballasts are likely to become even more popular.

Programmed-start ballasts operate on a circuit similar to rapid-start, but provide precise heating of the lamp filaments and controlling the pre-heat time before applying starting voltage to ignite the lamp. This reduces filament stress during lamp startup phase, maximizing lamp life and making this type of ballast ideal for frequently switched applications such as a space where occupancy sensors are installed.

The Next Generation Has Begun

Already a new generation of electronic ballasts is emerging, introduced over the past few years, taking the evolution of this technology to the next level. Ballasts are steadily becoming smaller, smarter and more flexible. New creations include digital ballasts that can be networked to computers for computer controlled dimming and switching; "adaptable" ballasts, which can operate different types and quantities of lamps on various voltages; and high-efficiency electronic ballasts which, when combined with the new "super T8" lamp, can result in 15-20 percent energy savings versus conventional T8 lamps and electronic ballasts.

Meanwhile, dimmable ballasts are expected to become more popular as building owners and managers learn more about and continue to drive the demand for facilitywide dimming solutions. Dimming saves energy, presents excellent load shedding opportunities, and can result in greater flexibility.

In this article, we will concentrate on "super T8" lamp-ballast systems and "adaptable" ballasts.

Howard Wolfman, PE, Sr. Manager, Regulatory Affairs for OSRAM SYLVANIA Products, Inc., sees electronic ballast technology evolving towards fewer models with each model having greater capabilities, smaller and more multifunctional.

"Today, the mainstream products -- e.g., instant start T8 ballasts representing 85-90% of the market, are still mostly discrete voltage models due to initial cost considerations by luminaire manufacturers," he said. "Although the mainstream ballast models are single voltage, they operate 1-4 lamps and lamp type combinations from 13-40W. Today, we have ballast models that are multiple voltage, models that operate multiple lamps, models that operate multiple wattage lamps; in the future, these will be combined into a single set of models. The remaining 10-15% of the market consists of spec models that already offer universal voltage/multilamp/multiple lamp type operation. These models include programmed start T8 and T5 ballasts, and rapid start ballasts."

Stuart Berjansky, Product Manager, Dimming for Advance Transformer, sees digital technology as the key to miniaturization and greater capabilities. "Electronic ballast technology over the next five years will lead us down a digital path that will open new horizons for the lighting industry," he said. "The future lends itself towards miniaturization with increased capabilities. The digital path will enable this to happen. Additionally, our suppliers continuously develop new components that are smaller, which obviously helps us to meet our size reduction requirements. The digital ballast will allow the lighting system the ability to enable other building systems. Every room contains a light fixture, often fluorescent-digital systems allow us to use it as a sender/receiver of information."

Mike Kurczak, Product Manager for Advance Transformer, says, "More electronic ballasts will be available for the very large and very small lamps that have been ignored so far. T5 and T5HO ballasts will continue to evolve into a common footprint. And flexible ballasts will become more popular. All new lamps are being specified by the lamp manufacturers to operate on electronic ballasts, mainly programmed start to let their lamps last longer."

"The opportunity to develop and market truly intelligent lighting solutions is now possible with digital technology," said Janice Rewers, Marketing Communications Manager for Universal Lighting Technologies. "It opens the door to new designs and emerging solutions that allow the user to control their own lighting environments, improve their productivity and achieve bottom line results by reducing their overall energy costs."

Adaptable Ballasts

The fluorescent ballast's job is to provide sufficient voltage to start the lamp and regulate the current flowing through the lamp during operation. An important task during ballast specification is to ensure that its output characteristics match the lamp requirements so as to achieve the rated light output and lamp life. These requirements include lamp type, lamp quantity and input voltage.

A typical ballast, therefore, might be designated to operate two four-foot T8 lamps at 277V. In a large facility, the fixtures may house a variety of ballast types.

The adaptable ballast was designed to simplify and consolidate inventory -- a benefit to end-user, contractor, fixture manufacturer and distributor -- by providing a single device that can operate varying combinations of lamp types, quantities and input voltages.

Also called "universal voltage" ballasts, these ballasts eliminate problems due to installation errors when fixtures and ballasts are wired to the incorrect line voltage (a single ballast can be supplied to projects with mixed line voltages). And adaptable ballasts aid the end-user in operations flexibility, enabling the lamps to change in existing fixtures to accommodate new space needs without also changing the ballast, and to add or remove lamps to adjust light levels to space needs, as opportunity presents, for energy savings.

"As ballast manufacturers have been able to bring dedicated voltage and multivoltage ballast costs closer together, fixture manufacturers have begun to adopt multivoltage ballasts," said Berjansky. "The fact that these ballasts also operate multiple lamps and types draws further interest."

Advance Transformer's new Centium electronic ballast (ICN-2S28), which is adaptable to multiple input voltages, multiple lamp wattages and multiple number of lamps. The ballast features Advance's IntelliVolt® technology, which allows 120V through 277V operation at either 50 or 60 Hz. This programmed-start ballast can operate one or two 14/21/28/35W T5 lamps. According to the company, the Centium ICN-2S28 provides consistent, full-light-output ballast factor, regardless of whether one or two lamps are being operated. In addition, it features a low-profile enclosure one inch in height.

Advance manufactures SmartMate®, a family of compact fluorescent electronic ballasts that operate at universal input voltage from 120V to 277V at 50 or 60 Hz, and are adaptable to multiple lamp wattages and multiple number of lamps. The company also manufactures electronic metal halide ballasts for multiple voltages (120/277) along with multiple lamps (39/50W and 70/100W). In addition, Advance's Dynavision ballast is available to operate 320/350/400W metal halide lamps.

Figure 3.  SmartMate compact fluorescent electronic ballasts from Advance Transformer

Universal Lighting Technologies' Triad universal input voltage ballasts provide the convenience of universal voltage as a standard feature. This technology incorporates the intelligence to send the input voltage and regulate the input current to the ballast so that the output control to the lamps remains consistent across the entire range (108-305).

"The low-profile package and small cross section allow for greater fixture design flexibility and instant start operation maximizes energy savings," said Rewers.

Figure 4.  Triad Universal Voltage Ballast from Universal Lighting Technologies

Universal Lighting also offers a comprehensive line of electronic compact fluorescent ballasts that provide universal input voltage at 50 or 60 Hz. These ballasts also operate multiple (1 or 2) lamps, feature programmed-start rapid start technology to maximize lamp life, and feature auto-reset for safe operation at end-of-life. They are designed for 90ºC maximum allowable case temperature and available for 13-70W lamp applications.

Figure 5.  Triad Compact Fluorescent Ballasts from Universal Lighting Technologies

OSRAM SYLVANIA's Quicktronic Universal Voltage electronic lamp and ballast systems operate at input voltages from 120V to 277V and are available for T4 compact fluorescent, T5, T5HO and T8 lamps. According to the company, these systems provide similar output to dedicated-voltage systems. They also feature programmed-start operation for up to 100,000 starts, ideal for operation with occupancy sensors. OSRAM SYLVANIA also manufacturers Universal Voltage systems for 39/70/100W metal halide lamps and 100/150W Icetron lamps.

Figure 6.  Quicktronic Universal Voltage Ballast from OSRAM SYLVANIA

Super T8 Lamp-Ballast Systems

Super T8 lighting systems are comprised of a high-lumen, extended-life T8 lamp used in combination with a reduced-power electronic ballast. Combined, the Super T8 system's wattage is 15-20 percent less than a standard T8 system, according to Commercial Lighting Retrofits: A Briefing Report for Program Implementers, published in April 2003 by the American Council for an Energy-Efficient Economy (ACEEE).

Therefore, while the Super T8 system is made possible by the new high-lumen T8 lamp, it can be married to existing, proven reduced-power electronic ballasts to create a new, powerful energy-saving system.

Compared to a system comprised of energy-efficient magnetic ballasts driving 34W fluorescent lamps, the new standard after EPACT 92 and the 1988 Federal Ballast Energy Law, Super T8 systems can produce energy savings as high as nearly 40 percent. These energy savings represent virtually the same opportunity as existed before EPACT, when standard T8 systems began to be used for retrofit of magnetic ballast/F40T12 lamp systems.

Jim Benya, IALD, principal of Benya Lighting Design, wrote in the January/February 2003 issue of Architectural Lighting, "To identify a Super T8, look for lamps that are at least 3100 initial lumens [as opposed to 2850 for a standard T8] and have a barrier coat design and high lumen maintenance." A Super T8 lamp has an improved lumen maintenance with 88-92 percent end-of-life lumens (ACEEE).

Super T8 lamps include the SYLVANIA "Xtreme," Philips "Advantage" and GE "HL." Ballasts include the SYLVANIA "Xtreme," Advance "Optanium," Universal Triad "HE" and GE "UltraMax."

How are energy savings achieved with Super T8 systems? Super T8 lamps produce around 3100-3200 lumens versus 2850 for a standard T8. With the higher light output, a reduced-power electronic ballast can be used that has a lower ballast factor and lower wattage. For example, a standard T8 operating on a ballast with a ballast factor of 0.88 will produce 2508 design lumens; a Super T8 (3100/3200 initial lumens) operating on a reduced-power ballast with a ballast factor of 0.78 will produce 2418 or 2496 lumens. The result is both lamp-ballast systems will produce approximately the same light output, while the Super T8 system operates on 15-20 percent less wattage, which means greater energy savings. (Or, if less light output is acceptable, a standard T8 lamp with a reduced-power ballast can be specified.)

In Table 1, we see a comparison of standard T8 and Super T8 systems. In Table 2, we see a comparison of a Super T8 and an energy-efficient magnetic ballasted 34W fluorescent system.

Table 1. Comparison of standard T8 and Super T8 systems. Source: Walerczyk, S. and B. Liebel, 2002: "Cutting-Edge Retrofitting and Relighting." Seminar presentation at Lightfair International 2002, June 2, San Francisco, CA.

Table 2. Comparison of Super T8 and today's "standard," energy-efficient magnetic ballasts driving 34W F40T12 lamps. The wattage range for the 4-ft. Super T8 system is based on whether a universal-voltage ballast is used, which consumes 1 more watt per ballast. Source: Universal Lighting Technologies, 2003.

The ballast may be instant-start or programmed-start. The ballast may also be adaptable and offer the benefits of operating with universal input voltage and multiple lamps and lamp wattages.

[If instant-start is preferable, the specifier can also consider a 30W T8 system for to achieve energy savings -- about 52W for a (2) lamp/(1) full light output ballast system compared to a typical system's 58-59W. OSRAM SYLVANIA also offers a 28W T8 lamp for operation with instant-start and programmed-start ballasts that produces 2725 initial lumens and a maintenance factor of 94 percent; when operated with a reduced-power ballast, power consumption is 24 percent lower than a standard reduced-power instant start system with a six percent reduction in lumens, ideal for applications where a slight reduction in light levels are acceptable.]

A good example of a Super T8 system is the Xtreme system from OSRAM SYLVANIA, which marries Octron XPS Ecologic lamps with Quicktronic ProStart electronic ballasts. The lamps are rated at 3200 initial lumens, 86 CRI, 3000/3500/4100K CCT, pass TCLP, 93 percent lumen maintenance at 12,000 hours, up to 96 LPW (maintained), and a service life of 30,000 hours. The Quicktronic ProStart electronic ballast is adaptable to voltage (120-277V), has a ballast factor of 0.74, is programmed-start, and draws 48W of power compared to a typical system's 58-59W.

"We have seen a huge interest in the SYLVANIA Xtreme system for specific project applications," said Wolfman. "When the user or specifier is educated regarding the long-term cost benefits of energy efficiency, they make the best decision. When they are not educated, they fall back on the decision being made on the basis of first cost."

Figure 7.  Xtreme system from OSRAM SYLVANIA

Another example is the Philips Advantage Universal Start Ultimate Performance Lamp operating with an Optanium ballast from Advance Transformer. The lamps are rated at 3100 initial lumens, 30,000 hours rated life, passes TCLP, 3000K and 86 CRI. The ballast can be instant start or programmed start, adaptable to voltage (120-277V) for programmed start, have a ballast factor of 0.78 or 0.88, ability to start at temperatures as low as 0ºF/-18ºC, and draws 48W (0.78 BF) to 55W (0.88 BF) of power compared to a typical system's 58-59W.

"The pairing of a high-lumen lamp and energy-efficient electronic ballast creates a unique system," said Berjansky. "We have received a lot of interest in the Optanium ballast regarding this combination."

Figure 8.  Optanium ballast from Advance Transformer

Universal Lighting offers ULTIM8 ballasts, ideal for new construction or retrofits; when paired with energy-saving or Super T8 lamps, these high-efficiency ballasts cost 40% less to operate than T12 energy-saving systems and up to 8% less than standard electronic systems, with comparable light output.

Figure 9.  ULTIM8 High Efficiency Family of Ballasts from Universal Lighting Technologies

Energy Savings Opportunities More Compelling Than Ever

As the states move to adopt tough energy codes in 2004 at least or more stringent than the ASHRAE/IES 90.1-1999 Standard, T8 and T5 lamps and electronic ballasts will increasingly become the standard for new construction. Now specifiers and users can accelerate energy savings by another 15-20 percent by choosing Super T8 systems for applications where the light output of a standard T8 system is desired -- and simplify specification, installation and maintenance, while increasing application flexibility, by choosing Super T8 systems driven by adaptable reduced-power ballasts. And for programs such as the U.S. Green Building Council, whose LEED certification program's energy section points is predicated on exceeding the ASHRAE/IES 90.1-1999 Standard, Super T8 systems are an ideal choice to gaining these hard-earned points.

All things considered, Super T8 systems, combined with occupancy sensors and dimming controls, are one of the most energy-efficient lighting systems available today.

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