TROUBLESHOOTING FLUORESCENT LAMP BALLASTS

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Pages 31-49 from the Advance Transformer Co. FLB Pocket Guide

TROUBLESHOOTING ELECTRICAL TEST EQUIPMENT

Note: Voltage and current measurements present the possibility of exposure to hazardous voltages and should be performed only by qualified personnel. The following equipment is recommended for testing fluorescent fixtures: True RMS Voltmeter Ranges: 0-300-1000 Volts AC Ammeter (clamp-on type acceptable) Ranges: 0-10 Amperes AC Multi-meter (with voltage and current ratings as shown above) Frequency: 60Hz for electromagnetic, above 20kHz for electronic

TROUBLESHOOTING
Any work performed on the lighting system, including inspection, troubleshooting and maintenance, should be done with the fixture properly de-energized and the circuit locked and tagged according to Occupational Safety and Health Act (OSHA) requirements.

TROUBLESHOOTING GENERAL INSTALLATIONS

INOPERATIVE FIXTURE
Often when a fixture becomes inoperative, the cause is not attributable to the ballast. It is therefore important to examine all components of the fixture before removing the ballast for replacement. The following procedure is recommended:

TROUBLESHOOTING FLUORESCENT APPLICATIONS

SAFETY FIRST: Troubleshooting procedures must take place within these guidelines: Those working on the fixtures (and hence, in situations where they may be exposed to hazardous voltages) must be properly qualified to perform such work. Ballasts, starters, capacitors and fixtures must be grounded in accordance with the National Electrical Code (NEC). In the case of fluorescent ballasts, the case must be grounded either to the fluorescent fixture or, if remote mounted, by other means such as a wire from ballast case to ground. Without proper fixture and ballast grounding, a shock hazard may exist due to the fluorescent fixture becoming energized by an internal ballast failure. In addition, all ballasts have normal leakage. When the ballast is properly grounded, the leakage current does not constitute a hazard.
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1. Change or check all lamps to ensure satisfactory operation. 2. As lamps are removed, examine all sockets to ensure proper and positive contact with lamp pins. 3. If starters are used, each starter should be checked and replaced wherever necessary. 4. Examine all connections within the fixture to ensure their conformance with the wiring instructions appearing on the ballast. 5. Examine and test ballast.

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TROUBLESHOOTING

TROUBLESHOOTING

LAMPS NOT STARTING

Replace Lamps With Known Good Lamps Lamps Light If Lamps Were Recently Replaced, Go To "Measure Voltage At Sockets"

New Lamps Do Not Light

TROUBLESHOOTING GENERAL INSTALLATIONS

Open Channel Cover To Visually Inspect Condition Of Ballast And Connections. Check Lamps And Ballast For Matching
Everything Okay

If Improper Correct

Measure Voltage At Sockets Using Tables On Pages 39,41,44 & 45

Everything Okay

No Voltage At Any Socket

Voltage Out Of Tolerance

All Voltages Measure Low

Check Grounding Of Fixture And Ballast

Check Supply Voltage And Fuse or Circuit Breaker

Cut Leads To Socket With Voltage Out Of Tolerance Measure Voltage At Ballast

Check Supply Voltage

Everything Okay

Everything Okay

Check Spacing Between Lamps And Sockets Lamp Must Be Seat In Socket
Everything Okay

Replace Ballast

Voltage At Ballast Out Of Tolerance Replace Ballast Voltage At Ballast Within Tolerance Problem With Wiring Or Socket

Low Supply Voltage Check Power Distribution System

Close Fixture Lamps Should Light

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TROUBLESHOOTING CYCLING
The National Electrical Code stipulates that most ballasts installed indoors must contain a cut-out device that protects the ballast from overheating. If abnormal ambient conditions cause the ballast to overheat, the thermal protection devices switch disconnects the ballast from the line. Once cooled, the ballast is reconnected and restarts the lamps. If the conditions persist, the ballast will switch off again repeatedly in a process called cycling.

TROUBLESHOOTING

TROUBLESHOOTING GENERAL INSTALLATIONS

LAMP CYCLING
Open Channel Cover To Visually Inspect Condition Of Ballast And Connections. Check Lamps And Ballast For Matching Everything Okay If Improper Correct

Measure Ambient Temperature Everything Okay

High Ambient Temperature

Check For Insulation Above Fixture

Remove Insulation

Check Supply Voltage Everything Okay

High Supply Voltage Consult Power Company

Reduce Ambient Temperature Or Replace Ballast With A Cooler Operating Ballast

If Not Possible Replace Ballast With Cooler Operating Ballast

Ballast May Be Inoperative

Test Ballast Electrically

Remote Mount Ballast

Remote Mount Ballast

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TROUBLESHOOTING LAMP SWIRLING

Another problem that may occur is a process known as swirling or spiraling, where light does indeed appear to swirl or spiral inside the tube. This is normal for some lamps when first lighted, and in these cases the problem will correct itself after a few hours of operation.

TROUBLESHOOTING PREHEAT
To measure starting current and operating current, the ammeter must be connected between the colored high voltage secondary lead of the ballast and the lamp. To determine starting voltage, remove lamp and connect voltmeter between respective primary and secondary leads of each lamp according to ballast wiring diagram.

TROUBLESHOOTING PREHEAT INSTALLATIONS

This problem may also be caused by cold temperatures. In this case, the lamps may need to be jacketed or otherwise shielded from the cold drafts. Also, check that the lamps are rated for the actual temperature measured. This problem may also be caused by low input voltage; check and correct. Next, check for ballast and lamp compatibility and replace the wrong component. Replace lamp with known good lamp. If condition still exists, change ballast.

Lamp Type F4T5 F6T5 F8T5 F13T5 F14T8 F14T12 F15T8 F15T12 F18T8 F19T8 F20T12 F25T12 F30T8 F40T12 F90T17

Operating Current (Ampere) .17 .16 .145 .165 .365 .38 .305 .325 .385 .355 .38 .46 .355 .43 1.50

Starting Current (Ampere) .16-.25 .16 -.25 .16 -.25 .18 -.27 .44 -.65 .44 -.65 .44 -.65 .44 -.65 .35 -.80 .35 -.80 .44 -.65 .41-.95 .40-.65 .55 -.75 1.45 - 2.2

Starting Voltage (Minimum) (Open Circuit) 108 108 108 180 108 108 108 108 108 108 108 108 176 176 132

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TROUBLESHOOTING TROUBLESHOOTING PREHEAT INSTALLATIONS

One of the major causes of trouble with a Preheat circuit is the miswiring of the fluorescent ballast. This condition can be noted by short lamp or starter life, non-starting of lamp, or premature failure of the ballast. For example, with a two lamp ballast, the starter leads from the two pairs of lamp holders may be crossed. If both starters open at the same time, the lamps will start. However, if one lamp starts before the other, the nonstarting lamp may blink on and off for a long time before starting if it will start at all. To determine if wired correctly, short the terminals of a fluorescent starter with a fine bare wire. Remove all starters from the fixture but leave the lamps in. Insert the shorted starter in one starter slot. If the fixture is wired properly both ends of the same lamp will glow. If crosswired, one end of each lamp will glow.
S Lamp S Lamp S Lamp S Lamp

TROUBLESHOOTING
Other causes of difficulty could be (1) low or high circuit voltage, (2) improper lamp holder contact, (3) pinched wires or (4) improper lamps.

TROUBLESHOOTING SLIMLINE & INSTANT START INSTALLATIONS

SLIMLINE & INSTANT START

To determine starting voltage, the lamp must be removed and voltmeter connected between the respective primary and secondary leads of each lamp as designated on ballast label. For series-sequence ballasts, the red lead must be in position while measuring the starting voltage of the remaining lamp.
* Starting Voltage (Minimum) 270 315 385 385 405 385 540 540 475 675 675 565

Lamp Type F24T12 F36T12 F40T12/IS F40T17/IS F42T6 F48T12 F64T6 F72T8 F72T12 F96T8 (200mA) F96T8 (265mA) F96T12

Black White

Ballast

Red Blue

Black White

Ballast

Red Blue

Crossed Starter Leads

Correct Wiring

There have been many installations of Preheat fluorescent lighting in which two lamp ballasts are operating with one lamp on and one lamp out, or with shorted starters. These conditions will cause premature ballast failures due to the ballast coils being operated above their coil temperature limitation. Thus it is advisable that all inoperative lamps and starters be immediately replaced.

* For Single Lamp, measure voltage between Red & White leads. For Two Lamp (SERIES SEQUENCE), measure voltage between Red & White Insert lamp in Red & White position, then read voltage between Blue & Black. For Two Lamp (Lead Lag), measure voltage between Red & White and Blue & White leads. For Electronic (parallel), measure voltage between Red & Blue leads.

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TROUBLESHOOTING TROUBLESHOOTING SLIMLINE & INSTANT START INSTALLATIONS

There are two common electromagnetic ballast circuits for the two lamp operation of Slimline lamps: The Lead Lag circuit and the Series Sequence circuit. Electronic ballasts operate the lamps in parallel. The Lead Lag Slimline Ballast operates one lamp independently of the other. Thus, if one lamp becomes inoperative, the other lamp will still light. There are two legs in the Lead Lag circuit: one leg of the circuit is called the lead section and contains an inductive coil and a capacitor in series with the lamp. The other leg just contains an inductive coil and is called the lag section. This is how the name Lead Lag was derived. It is permissible to use Lead Lag Slimline Ballasts for starting of Slimline lamps down to temperatures of 0F and above. The Series Sequence Slimline Ballast was introduced in order to reduce the size, weight, and cost of the Slimline Ballast. In this circuit two lamps are operated in series, with the lamps starting in sequence. If one lamp becomes inoperative the other will not fully light or light at all. Short lamp life or premature end blackening can be due to (1) low supply voltage, (2) improper lamp-socket contact or (3) miswiring of the ballast. The open circuit voltage of a Slimline Ballast, in many cases, is great enough to start a lamp with one lamp filament de-activated. This lamp will become extremely black at one end and will flicker. If the lamp is not replaced, the ballast will overheat and eventually fail.

TROUBLESHOOTING
If an Electromagnetic Slimline Ballast is operated with one lamp on and one lamp off, the ballast will experience higher coil temperatures which could result in premature ballast failures. In cases of short ballast life, check this factor. Electronic Slimline ballasts generally are not effected by lamp failure.
Lamp Lamp Red Series Sequence| Ballast Blue White Black Lamp

TROUBLESHOOTING SLIMLINE & INSTANT START INSTALLATIONS

White Black

Lamp

Lead Lag Ballast

Red Blue

CORRECT

CORRECT

Lamp

White Black Series Sequence| Ballast

Red Blue

Lamp

INCORRECT

Lamp

Lamp

White Black Series Sequence| Ballast

Red Blue Red Lamp

Wh. Lamp Blk.

Parallel Ballast

Blue Blue

INCORRECT

CORRECT

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TROUBLESHOOTING RAPID START

To measure starting voltage, connect voltmeter between the highest reading Red lead and Blue lead with lamp removed. To measure filament voltage on a single lamp unit, read voltage between Red-Red and Blue-Blue leads. For two lamp units, read voltage between Red-Red, Blue-Blue and Yellow-Yellow leads.
Starting Voltage (Minimum @ 50 F) Single Lamp 108 108 108 108 140 170 200 150 200 250 200 200 150 180 200 205 Two Lamp 157 157 157 157 210 260 256 215 300 385 256 256 225 230 230
Rapid Start 800 & 1500 MA. Lamp Type F24T12/HO F36T12/HO F48T12/HO F60T12/HO F72T12/HO F84T12/HO F96T8/HO F96T12/HO F48PG17/VHO F48T12/VHO F72PG17/VHO F72T12/VHO F96PG17/VHO F96T12/VHO

TROUBLESHOOTING

Rapid Start 430 MA. Lamp Type F14T12 F15T8 F15T12 F20T12 F17T8 F25T8 F25T12 F30T12 F32T8 F40T8 F40T10 F40T12 FC6T9 FC8T9 FC12T9 FC16T9 FC8T9 & FC12T9 FC12T9 & FC16T9

Filament Voltage 7.5 - 9.0 7.5 - 9.0 7.5 - 9.0 7.5 - 9.0 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5

Starting Voltage (Minimum) Single Lamp Two Lamp -20 F 0F 50 F -20 F 50 F 0F 225 145 110 140 85 195 260 195 155 115 190 235 310 256 203 240 155 290 325 365 240 210 290 350 420 395 283 340 260 410 455 430 330 280 360 445 775 450 490 465 330 360 295 480 160 160 225 225 300 300 205 205 270 270 355 355 240 240 310 310 400 400 250 250 350 350 470 470 265 265 360 360 470 470 300 300 400 400 500 500

Filament Voltage 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.6 - 4.8 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5 3.4 - 4.5

TROUBLESHOOTING RAPID START INSTALLATIONS

NOTE: Electronic ballasts generally provide starting voltages higher than those listed in the above tables. These open circuit voltages are listed on the ballasts label. Filament voltages for electronic and electromagnetic ballasts are the same.

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TROUBLESHOOTING TROUBLESHOOTING RAPID START INSTALLATIONS

The Rapid Start circuit (described on page 7) eliminates the annoying flicker associated with starting Preheat systems. Rapid Start circuits also simplify maintenance since no starter is used. The Rapid Start lamp operates on the principle of utilizing a starting voltage which is insufficient to start the lamps while the cathodes are cold but is sufficient to start the lamps when the cathodes are heated to maintain emission temperature. This voltage range between starting cold and starting hot is a very narrow band of voltage which must be closely controlled in order to prevent either failure of the lamps to start or instant starting of the lamps with cold cathodes which is detrimental to the lamps. In order to stay within this range of voltage, it is necessary to excite the gas within the lamps by means of an external voltage which is applied to the gas within the lamps to create ionization. This external excitation is created by means of the capacity that is present between the lamp and the reflector or channel. In order to act effectively, the fixture must be connected to ground and the white lead of the ballast connected to ground lead of power supply. Thus it is stated on the label of Rapid Start ballasts MOUNT LAMPS WITHIN 1/2 INCH (3/4 INCH or 1 INCH) OF GROUNDED METAL REFLECTOR. The majority of new fluorescent installations today use ballasts of the Rapid Start design. The HIGH OUTPUT (800 MA), and VERY HIGH OUTPUT (1500 MA) lamps are of the Rapid Start design.

TROUBLESHOOTING
Refer to the figure on page 48. BLUE-BLUE, YELLOWYELLOW, RED-RED LEADS are the built-in filament windings which supply a voltage of 3.4 to 4.5 volts to the lamp cathodes. If the cathodes are not properly heated, premature lamp end blackening will result. The lack of heating could be due to:

TROUBLESHOOTING RAPID START INSTALLATIONS

1. 2. 3. 4. 5. 6. 7. 8. 9.

Improper seating of the lamp within the socket. Broken sockets. Broken lamp pins. Too great of socket spacing. Damaged lamp cathode(s). Ballast lead wire not properly connected to socket. Low supply voltage. Inadequate ballast filament voltage. Improper wiring.

To determine if there is adequate voltage at the lamp cathodes, measure the voltage at the socket terminals. The voltage at the sockets should read between 3.4 and 4.5 volts. If there is adequate voltage, the lamp end blackening can be due to conditions 1, 2, 3, 4, or 5. If the voltage is not adequate it can be due to one or more of conditions 6, 7, 8, or 9. If random starting of Rapid Start lamps is experienced, be sure the fixture is properly grounded. As previously stated, for completely reliable starting in Rapid Start circuits it is necessary to have a starting aid. The starting aid should be an electrically grounded metal strip at least 1 inch wide and extending the full length of the lamp. The lamp should be within 1/2 inch of the grounded strip for 40 watt lamps and smaller, (3/4 inch for T8 lamps) and 1 inch for higher output lamps.
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TROUBLESHOOTING
If, under high humidity conditions, Rapid Start lamps start slowly or do not start at all although the cathodes are properly heated, this may be due to dirt on the lamps which is offsetting the silicon coating on the lamps, or it may be due entirely to a poor silicon coating. If it is a new installation (in operation only a few months) which experiences random starting under high humidity conditions, in most cases it will be due to low supply voltage or poor silicon coating on the lamps. When random starting is experienced under high humidity conditions in an installation in operation for a longer period of time this is usually due to dirt on the lamps. The lamps should be washed in water to remove the dirt. Sometimes with a two lamp Rapid Start series ballast only one lamp will light to full brilliance and the other will not light. Refer to the figure below. If the lamp between the Red leads and Yellow leads is lit and the other lamp is out, look for a pinched Yellow lead. If the lamp between the Red and Yellow leads does not light and the other does, it is probably due to a short within the ballast.
LAMP BLUE BLUE YELLOW YELLOW LAMP RED RED

TROUBLESHOOTING MODIFIED RAPID START

This type of ballast starts and operates the lamps similar to Rapid Start Ballasts, so troubleshooting on pages 44-48 would also apply. The only difference is that filament heating is reduced or eliminated after the lamps ignite so the 3.4-4.5 volts specified cannot be measured during normal operation. Also, some two lamp ballasts require that only one lamp be removed when measuring starting and filament voltages. If both lamps are removed, these voltages cannot be accurately measured.

TROUBLESHOOTING RAPID START INSTALLATIONS

INSTANT START OF RAPID START LAMPS

This type of ballast does not provide filament heating to the lamps. Only the starting voltage which is listed on the ballast label can be measured when the lamp is removed. The wiring of this ballast requires that the lamp filaments be shorted together and then connected to the ballast to obtain rated lamp life. If the filaments are not shorted, the lamps will ignite properly but fail prematurely. Rated lamp life when using this Instant Start Ballast may be reduced vs. a Rapid Start Ballast depending on how frequently the lamps are started.

BLACK

WHITE

FIG .I

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Advance Transformer Co. OHare International Center 10275 West Higgins Road Rosemont, IL 60018 Tel: 800-322-2086 Fax: 800-423-1882 Customer Support / Technical Service: 800-372-3331