Phase 2 Test Procedures
Reflector CFLs (R-CFL) provided by manufacturers in response to the U.S. Department of Energy's Pacific Northwest National Laboratory (PNNL), Technology Innovation Competition 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 minimum mandatory technical requirements.
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.
- Perform elevated temperature life testing on a minimum sample size of 10 units per model.
A total of 31 models representing four manufacturers were submitted in response to the request for proposal. Each model was moved into short-term testing for thermal evaluation. A total of 23 models were moved into Elevated Temperature Life Testing (ETLT).
Short-Term Thermal Test
Short-term testing was conducted as follows: Lamps were initially operated at 25°C to establish the baseline light output corresponding to the rated luminous flux determined under LM-66-00. Lamps were then operated at 55°C to simulate the conditions of the insulated ceiling rated airtight (ICAT) environment.
- 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.
- 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.
Elevated Temperature Life Testing
R-CFLs that move into ETLT are subjected to a minimum of 6,000 hours of operation in a simulated ICAT environment (laboratory testing). 6,000 hours is a minimum requirement for both this competition and the ENERGY STAR CFL Program. Models with rated life claims beyond 6,000 hours are required to continue testing until that claim is met. Ten lamps of each model are tested, and manufacturers are required to pay testing costs.
The elevated-temperature life testing procedure is identical to (IESNA 1991a) LM-65-91 except that the ambient temperatures are maintained at 55°C ± 10°C, versus the 25°C ± 10°C 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:
- Maintains ambient temperature in the plane of the lamps at 55°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 at least 6,000 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.
- Light intensity for each lamp is measured every two weeks throughout the ETLT process to evaluate lumen depreciation over time.
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.