Test Procedures & Results – Phase 1
Reflector CFLs (R-CFL) provided by manufacturers in response to Pacific Northwest National Laboratory's (PNNL) competitive solicitation were evaluated both against the minimum requirements detailed in the technical specifications and successful completion of performance testing. Products first had to be ENERGY STAR certified or be eligible for ENERGY STAR certification and then were required to meet additional criteria aimed at addressing the performance issues identified above:
- Specification of the maximum warranted operating temperature
- Minimum 125°C rated electrolytic capacitor(s)
- Minimum electrolytic capacitor rated life of 5000 hours
- Maximum overall length (R-30 = 5.6"/R-40 = 6.6")
- Minimum luminous flux of 500 lumens (initial)
- Maximum beam angle of 120°.
If the lamp met the minimum requirements, it was forwarded to an independent testing facility, the Luminaire Testing Laboratory, Inc. (LTL, an independent luminaire testing laboratory located in Allentown, Pennsylvania) where it was subjected to two different laboratory tests: the "Short-Term Test" and, if successful, "Elevated Temperature Life Testing." The objectives of the laboratory tests were as follows:
- Determine the "thermal factor" corresponding to the reduction in delivered luminous flux by virtue of operation in the simulated insulated ceiling environment.
- Measure steady state ambient temperatures at a minimum of four elevations within the recessed downlight housing.
- Directly measure electrolytic capacitor(s) temperature(s) at steady state operating conditions.
- Perform elevated temperature life testing on a minimum sample size of 10 units per model.
A total of 12 models representing five manufacturers were submitted in response to the request for proposal. One model was deemed "non-responsive" for failing to meet ENERGY STAR and PNNL requirements. The remaining 11 products were moved into short-term testing for thermal evaluation. Based upon short-term testing results, a further three were removed from consideration for not delivering the advertised wattage and rated light output. Therefore eight models entered long-term testing.
Short-Term Test
The short-term test consisted of operating the R-CFL in a simulated insulated ceiling environment at full power for a minimum of six hours, while taking temperature measurements at several locations. Manufacturers provided one sample of each model, that was modified by the manufacturer with an "access port" to accommodate direct measurement of the electrolytic capacitor(s). Thermocouples where attached to the end of the capacitor via the access port. The short-term test was conducted using a thermal testing apparatus capable of the following:
- Maintain ambient temperature surrounding the apparatus at 25°C ± 1°C
(77°F ± 2°F). - Containment of loose-fill cellulose insulation to a minimum depth of 12".
- Fitted with an easily removable, tight closing lid gasketed for air tightness.
- Support the luminaire at a distance of 36" above the illuminance measurement plane.
- Automatically sample and record the ambient temperatures surrounding the lamp for a duration of six hours.
- Automatically sample and record the electrolytic capacitor(s) temperature for a minimum duration of six hours.
- Equipped with a photo sensing array consisting of a minimum of five illuminance meters located 36" below the thermal testing apparatus. One meter located directly below the center of the luminaire. The remaining four meters oriented 12" from the center meter and at 90° intervals from the center meter.
Additional Information on the Procedure
Elevated Temperature Life Testing
The elevated-temperature life testing procedure is identical to (IESNA 1991a) LM-65-91 except that the ambient temperatures are maintained at 60°C ± 10°C (140°F ± 18°F), versus the 25°C ± 10°C (77°F ± 18°F) prescribed in LM-65-91, to simulate the in-situ environment. Elevated-temperature life testing is being conducted using a testing apparatus (Figure 2) described as follows:- Capable of testing a minimum of 100 lamps.
- Maintains ambient temperature in the plane of the lamps at 60°C ± 10°C.
- Automatically cycles power to all testing luminaries at a rate of three hours "ON" followed by 20 minutes "OFF" for a period of 6000 hours of lamp run-time.
- Automatically senses and records the catastrophic failure of each lamp within a resolution of one hour.
- Automatically records the ambient temperature in the plane of the lamps at a minimum of four locations.
- Prevents radiant heat exposure from adjacent lamps.
Figure 2. Drawing of the Elevated Temperature Life Testing Apparatus
Successful completion of elevated-temperature life testing will satisfy the performance testing phase of the evaluation process, at which time the manufacturers' names will be made public and product promotion will begin.
ETLT Results – Phase 1
At the end of June 2005, the eight R-CFLs that moved into elevated temperature life testing (ETLT) were subjected to a minimum of 6,000 hours of operation in a simulated insulated ceiling rated airtight (ICAT) environment (laboratory testing). 6,000 hours is a minimum requirement for both this program and ENERGY STAR. Models with rated life claims beyond 6,000 hours were required to continue testing until that claim was met.
Ten lamps of each model were tested. The testing apparatus operated the lamps in an automated cycle of three hours on, 20 minutes off, for the test duration. Lamps of 16 watts or less were tested at an ambient temperature of 55°C, while lamps over 16 watts were tested at 60°C (140°F). DOE measured light intensity for each lamp every two weeks throughout the long-term testing process to evaluate lumen depreciation over time.
Table 1. Elevated-Temperature Life Testing – Phase 1 Results
| Manufacturer ID | Model ID | # Failed (of 10) | Calculated "rated life" (hours) |
| A | 4A | 10 | 2376 |
| A | 4B | 9 | 1075 |
| A | 5A | 7 | 3466 |
| B | 8A | 8 | 4520 |
| B | 9A | 10 | 2595 |
| B | 10A | 10 | 2793 |
| Philips | EL/A/BR30 16-W | 3 | 10,000(a) |
| Philips | SLS/R40 20-W | 2 | 10,000(a) |
| FEIT | ELS 15R30H | 0 | 8,000(b) |
| (a)Testing terminated at 10,000 hours. | (b)Testing terminated at 8,000 hours | ||