www.intertek.com ©Intertek 2013, All Rights Reserved. 1

A Layman’s Guide to Understanding Changes in ENERGY STAR® Product Specification for Lamps V1.0 Requirements

Jacki Swiernik – Intertek Lighting Staff Engineer

September 2013

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Agenda

• About Intertek o Our Heritage o Our Extensive Global Network

• Timeline • Products Included / Not Included • Common Definitions • Biggest Test Changes

o Distribution Testing o Rapid Cycle Stress Testing o Elevated Temperature Life Testing o Elevated Temperature Light Output Ratio o Color Spatial Uniformity Testing o Dimming – Min and Max Light Output, Flicker, Audible Noise

• Family Grouping • Questions?

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Our Heritage

Caleb Brett founds a marine surveying business

1885

Thomas Edison establishes what is later renamed as the Electrical Testing Laboratories (ETL)

1896

Virginius Daniel Moody establishes Moody Engineering for construction and electrical engineering projects

1911

Intertek and Moody International join forces

2011

Intertek Today: Valued Quality. Delivered.

Today

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An Extensive Global Network

• FTSE 100 company in the Support Services sector

• Market capitalization at £5 billion

• Revenue generation of over £1.7bn in 2012

100 More than

countries

1,000 More than

laboratories and offices

33,000+ people

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Timeline for Compliance

• Final version effective September 30, 2014 By this date, if lamps are not recertified to Lamps V1.0, they could

be taken off the ENERGY STAR website. • Historically, ENERGY STAR program administrators tend to close off

submissions to old version ~9 months prior to effective date, to enable all stakeholders to prepare for new requirements.

• Intertek Recommendation: Partners or laboratories should not be testing to previous

versions as of December 2013 / January 2014.

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Included Products

• In layman’s terms, products included in Lamps V1.0 are lamps that are intended to replace incandescent lamps.

• Lamps contain integrated ballasts or drivers (Multifaceted Reflector (MR)-16 exempt).

• Lamps intended to connect to common electrical grid: o 120, 240, or 277 Vac

o 12, 24 Vac or Vdc

• Includes lamps with following ANSI standard base types: E26, E26D, E17, E11, E12, GU24, GU5.3, GX5.3

E26 E17 E11 GU24 GU5.3 “medium

screwbase” “intermediate

base” “candelabra

base” “heavy 2 pin” “light 2 pin”

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Excluded Products

• Lamps that operate only on external power sources. • Linear LED tubes intended to replace fluorescent tubes. • Lamps not intended to tie in to electrical grid (i.e. solar only,

battery only). • Lamps with bases not covered in ANSI standards and base

types not listed on page 1 of Lamps V1.0. • Lamps incorporating power-consuming features which do not

provide illumination (ex: audio, air fresheners).

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Common Definitions – Omnidirectional

OLD

CFL categories = “bare” or “covered”

NEW

Lamp that distributes light evenly in all directions = “omnidirectional”

(picture credit – Osram Sylvania and Rambus)

Note: common

type of CFL

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Common Definitions – Directional

OLD

CFL categories = “indoor reflectors” or “outdoor reflectors”.

NEW

Lamp that distributes light primarily in one direction = “directional”.

(picture credit – Maxlite)

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Common Definitions – Directional for PARs and MRs

OLD

• CFLs = N/A

• LEDs = confusion about restrictions on beam angle in definition and center beam tool.

NEW

• All standard Parabolic Aluminum Reflector (PAR) and MR lamps (either source) must have at least 80% light output with a solid angle corresponding to a cone with an angle of 120° (= 60° zone).

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Common Definitions – Decorative

• A lamp with a candle-like or globe-like shape or lamps with purely decorative outside envelopes. o Note: may include those with A–shaped envelopes also, or

lamps with candelabra bases.

(picture credit – Osram Sylvania)

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Common Definitions – Reported

• In layman’s terms, “reported” = “rated”.

• May be ratings that appear on packaging and/or marketing materials.

• Per ENERGY STAR Directive 2011-05, reported values shall not be more efficient than measured.

o “Efficient” defined as “Efficacy” = Lumens per Watt

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Common Definitions – CFLS covered by DOE Regulations

• CFLS covered by DOE’s regulatory program = CFLs with medium screwbases that are not reflectors or 3-ways.

• When testing to federal regulations* (EPACT, etc.) testing must be performed by NVLAP accredited lab.

• Mostly comes into play with ratings (efficacy, lifetime, rounding, calculations, etc.).

* Refers to 10 CFR Part 430 Appendix W to subpart B, which refers to Energy Star V2.0.

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Common Definitions – Standard Lamp

• A “standard” lamp is an incandescent lamp whose dimensional outlines appear in an ANSI standard.

• Ex: A-lines, PARs, Rs, Globes, Candles, etc.

• Often known as the “replacement lamp” the energy efficient lamp is replacing.

• Energy efficient lamps must declare a standard lamp equivalent. The dimensions of the energy efficient lamp must fit inside the ANSI dimensional outline for

• Overall Length - Min and Max (OAL and MOL) (includes base)

• Maximum Diameter values (where they exist)

• Decorative: within +/- 15% of nominal diameter if no ANSI outline exists

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Common Definitions – Certification Points

• “Early Interim” certification point refers to the earliest point a lamp can be certified to carry the ENERGY STAR mark.

o For CFLs, this is at 4,000 hours (real-time)

o For LEDs, this is at 3,000 hours (real-time)

• “Full” certification point refers to the minimum point a lamp can fully be certified to carry the ENERGY STAR mark. This point may be longer for higher life ratings than minimums below.

o For CFLs, this is at 10,000 hours (real-time)

o For LEDs, this is at 6,000 hours (real-time, = 15K or 25K rated, depending on LED category)

3,000 hrs LED

4,000 hrs CFL

10,000 hrs CFL

15,000 – 25,000 hrs LED

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Common Definitions – Temperature Restricted

• Lamps that are “temperature restricted” are:

o Omnidirectional lamps that are labeled “not for use in enclosed fixtures” on the lamp and lamp packaging (or similar language).

o Any lamps that are labeled “not for use in recessed fixtures” on the lamp and lamp packaging (or similar language).

• Critical to know this rating up front for life testing temperatures.

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Common Definitions – Position Restricted

• Lamps that are “position restricted” are:

o Lamps that are only intended to operate in certain positions (ex: base up, etc.).

o Lamps that are tested in Life Test Apparatus Option A or Option B

Must indicate test position on packaging (or similar language).

• Critical to know this rating up front for life testing apparatus.

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Common Definitions – Distribution

• Distribution testing captures both the intensity of the light output and at the angle the light is coming from.

• The intensity of light is measured in the unit “candelas”.

• These candelas are grouped into vertical “zones” and lumens are calculated using formulas.

(graphic credit IES LM-79)

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Biggest Test Changes – Distribution

OLD • N/A for CFLs • Required for LED

Directional and Omnidirectional

NEW • Required for all LED lamps

and CFLs** of PAR and MR shapes

• CFLs omnidirectional and decorative exempt

• Some directional lamps have pass/fail criteria and some are just to set up for a different test such as color-spatial uniformity.

**Lamps V1.0 states in section 9.5 that CFLs are exempt from the Luminous Intensity Distribution requirements. However, all PAR and MR lamps (regardless of source type) are required to comply with 9.4 - Center Beam Intensity, and this comes from a distribution test.

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Distribution – Omnidirectional

OLD • N/A for CFLs • Required for LED

Omnidirectional • Candelas shall not

differ from the mean by more than 20% in 0°–135° zone

NEW • N/A for omnidirectional CFLs • Required for omnidirectional

LED lamps • In same 0°–135° zone: 90% of

the candelas shall not differ from the average by more than 25% and no single point shall vary by more than 50%

• Vertical angles at 5° maximum • 5% or more lumens shall be

emitted in 135°–180° zone

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Distribution Graphic – Omnidirectional

see page 24 of Lamps V1.0 – graphic credit EPA

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Distribution – Decorative

OLD N/A

NEW • N/A for decorative CFLs • Required for all

decorative LED lamps • No less than 5% of

lumens shall be emitted in the 110°–180° zone

• Includes globes

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Distribution Graphic – Decorative

(see page 24 of Lamps V1.0) – graphic credit EPA

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Distribution – Directional

OLD • N/A for CFLs • N/A for LED R, BR, ER,

and K types. • Required for LED PARs

and MR-16 lamps – used ENERGY STAR Center Beam Tool to calculate minimum required candelas.

NEW • Required for all PARs and MR-16

lamps – uses ENERGY STAR Center Beam Tool to calculate minimum required candelas.

• No requirements on zonal lumens (though there are some requirements in directional definition).

• Needed as a pre-test for Color Angular Uniformity for other LED Directional lamps.

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Biggest Test Changes – Rapid Cycles Stress Testing – CFLs

OLD • CFLs: 6 samples • One cycle = 5-minutes-

on, 5-minutes-off • Total number of cycles

= ½ of rated life • 5 out of 6 samples

must survive

NEW • CFLs: 6 samples • One cycle = 5-minutes-on, 5-

minutes-off. • For CFLs with a start time of

≤100 ms, total number of cycles = ½ of rated life, 5 out of 6 must survive

• Others: total number of cycles = same as rated life or 15,000 cycles max, 5 out of 6 samples must survive

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Biggest Test Changes – Rapid Cycles Stress Testing – LEDs

OLD • LEDs: 10 samples • One cycle = 2-

minutes-on, 2-minutes-off

• Total number of cycles = ½ of rated L70 life

• 9 out of 10 samples must survive

NEW • LEDs: 6 samples • One cycle = choice of 2-

minutes-on, 2-minutes-off or 5-minutes-on, 5-minutes-off

• Total number of cycles = same as rated life or 15,000 cycles max

• 5 out of 6 samples must survive

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Life Test Temperatures – 25°C nominal

• Lamps that are tested in nominal* 25°C ambient are:

o Decorative lamps

o Omnidirectional lamps < 10 W

o Any lamps that are “temperature restricted”

*CFLs tolerance on 25C = 15-40°C , LEDs tolerance on 25°C = 20-35°C

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Biggest Test Changes – Elevated Temperature Life Testing

OLD • For CFLs: only

required for indoor reflectors

• For LEDs: only required for directional and omnidirectional category ≥ 10W

NEW • Required for all

Omnidirectional lamps ≥ 10 W and all Directional lamps (any wattage)

• Exempt: products that are “temperature restricted”

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Option A – Elevated Temperature Life Testing – Recessed ICAT Cans

• Self heating.

• For omnidirectional lamps ≥ 10 W or directional lamps (any wattage).

• For lamps with “position restriction” on packaging.

• Sample size = 10 lamps base up.

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Option B – Elevated Temperature Life Testing – Grid Apparatus

• Nominal temperature of 45°C ± 5°C

o For omnidirectional lamps ≥ 10 W or directional lamps ≤ 20 W

• Nominal temperature of 55°C ± 5°C

o For directional lamps > 20 W

• For lamps with “position restriction” on packaging

• Sample size = 10 lamps base up

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Option C – Elevated Temperature Life Testing – “Hot House”

• Nominal temperature of 45°C ± 5°C

o For omnidirectional lamps ≥ 10 W or directional lamps ≤ 20 W

• Nominal temperature of 55°C ± 5°C

o For directional lamps > 20 W

• Best choice if a partner does not want to put position restriction or temperature restriction language on lamps or packaging

• Sample size = 5 lamps base up, 5 base down

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Biggest Test Changes – Elevated Light Output Ratio

OLD Required for indoor reflector CFLS only

NEW • Required for all directional

lamps that are not temperature restricted

• Lamp shall maintain ≥ 90% of initial light output at 25°C ± 5°C when tested in elevated life temps

• Can use Option A or B life apparatus, sphere, other equipment.

Example: if at 25C lumens = 1000, at elevated temp, lumens ≥ 900 to pass

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Biggest Test Changes – Color Angular Uniformity

OLD • N/A for CFLs • LED Directional Lamps:

o 2 horizontal planes 90° apart

o 10° vertical increments o Quit at beam edge (=50% of center

candelas)

NEW • N/A for CFLs • LED Directional Lamps:

o 2 horizontal planes 90° apart o 2° maximum vertical increments

for beam angles < 15° o 5° maximum vertical increments

for beam angles ≥ 15° o Continue over complete

distribution pattern

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Biggest Test Changes – Dimming Testing

OLD • N/A for CFLs • Involved in Operating

Frequency test only for LEDs

NEW • All lamps rated or marked as

dimmable • Maximum and Minimum

Light Output on Dimmer • Noise on Dimmer • Flicker on Dimmer

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Dimming Testing – Dimmer Sample Sizes

• For lamps designed for phase cut dimming (alternations to the line voltage to the lamp):

o 5 dimmers

o From at least 2 different manufacturers

o Representing various construction or consumer conditions o Ex: pre-set levels, forward-phase, reverse phase, rated 200W, rated

600W, etc.

• For lamps designed for non-phase cut dimming:

o Tested with all compatible dimmers listed on packaging

o Packaging must include “*” and point to an “only compatible with…” statement

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Dimming Testing – Other Information

• Lamps are tested with 1 lamp as load and again with 4 lamps as load

• 80% of tested lamp/dimmer combinations must pass • Dimming at maximum setting on a dimmer shall not drop

more than 20% light output when operated without a dimmer

• Dimming at minimum setting on a dimmer shall be no higher than 20% light output when operated at maximum dimming

• Highest percent flicker and highest flicker index shall be reported

• Noise shall not be above 24 dBA at 1 meter or less during dimming

Ex: Baseline (no

dimmer) = 1000 Lumens

High Dim ≥ 800 Lumens to pass

Low Dim ≤ (High

Dim Lumens * 0.20) Lumens to pass

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Dimming Tests – Visual Matrix – Most common dimmer configuration (phase cut) = 63 new tests

Lamp No.

Baseline (no

dimmer) Dimmer #1 Dimmer #2 Dimmer #3 Dimmer #4 Dimmer #5

1 Light Output

High Dim High Dim High Dim High Dim High Dim

1 Low Dim Low Dim Low Dim Low Dim Low Dim

1 + 3 lamp load High Dim High Dim High Dim High Dim High Dim

1 + 3 lamp load Low Dim Low Dim Low Dim Low Dim Low Dim

1 Flicker High Dim Flicker High Dim Flicker High Dim Flicker High Dim Flicker High Dim Flicker

1 Low Dim Flicker Low Dim Flicker Low Dim Flicker Low Dim Flicker Low Dim Flicker

1 + 3 lamp load High Dim Flicker High Dim Flicker High Dim Flicker High Dim Flicker High Dim Flicker

1 + 3 lamp load Low Dim Flicker Low Dim Flicker Low Dim Flicker Low Dim Flicker Low Dim Flicker

1 Noise High Dim Noise High Dim Noise High Dim Noise High Dim Noise High Dim Noise

1

Low Dim Noise Low Dim Noise Low Dim Noise Low Dim Noise Low Dim Noise

1 + 3 lamp load High Dim Noise High Dim Noise High Dim Noise High Dim Noise High Dim Noise

1 + 3 lamp load Low Dim Noise Low Dim Noise Low Dim Noise Low Dim Noise Low Dim Noise

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What is Flicker?

Flicker is a visible modulation of light output

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Dimming Note

There is a confusing note on page 19 of Lamps V1.0 that reads:

“For purposes of third-party certification, maximum lighting output, minimum lamp output, flicker and noise levels shall be reported by the partner to the certification body however documentation shall not be reviewed when products are certified or during verification testing. “

On 9/19/13, the EPA clarified this to mean that the dimming data can come from the partner (aka: first party) as long as it complied with all the data required in the related sections. Certification Bodies (CB) are to report this data, and only passing data will be accepted.

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Family Grouping – Allowable Variations

• Representative model and variant(s) must demonstrate correlation as follows:

1. Input current and input wattage ± 10% 2. Power factor ± 5% 3. Maximum overall length (base changes not included) ± 5% 4. Maximum overall diameter ± 5% 5. Safety listing report includes descriptions of both variant and

representative model demonstrating identical construction (except for allowed variations)

6. For LED lamps, average in situ temperature(s) of variants shall be no higher than 2.5°C from representative model

see page 7 of Lamps V1.0 for more details

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Family Grouping – Allowable variations

Attribute Allowable Variation Additional Test Data Required for Variant

Correlated Color Temperature (CCT)

• Allowed to share data where only variation is phosphor

• Representative model completes lumen maintenance and life testing

• Efficacy • Lumens • Elevated Temp Light Output

Ratio (if applicable) • Center Beam Intensity (if

applicable) • Distribution (if applicable) • CCT, CRI • Color Angular Uniformity (if

applicable) • Run-Up Time (CFLs only)

see page 7 of Lamps V1.0 for more details

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Family Grouping – Allowable Variations

Attribute Allowable Variation Additional Test Data Required for Variant

LED: Heat Sink Paint Color

Lamp body color pigment (not type of paint or plastic)

N/A

LED: Beam Angle Allowed if beam angle varies due to secondary optics - changes in material not allowed

• Distribution Data • Center Beam Intensity • Color Angular Uniformity

Lamp Base (ANSI) Allowed N/A

Decorative only: Envelope Shape

Allowed as long as material and thickness is unchanged

N/A

Decorative only: Envelope Finish

Allowed so long as material and thickness is unchanged

• Lumen Efficacy • Lumens • CCT, CRI

see page 7 of Lamps V1.0 for more details

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In Summary

• As soon as possible, contact your certified body for a “Technical Review” to sort family groupings and see what data will transfer to the new Lamps V1.0 specification.

• Some new tests will be likely, and at a minimum, your product might need to undergo the following tests: o CFL Lamps:

New Lumen Maintenance and Life Testing if previously rated < 10,000 hours (or omnidirectional lamp category may fall into elevated temperature category)

New Rapid Cycle Stress Test Distribution Test for Directional lamps New Dimming Tests (if rated)

o LED Lamps: Distribution for Omnidirectional and Decorative categories New Rapid Cycle Stress Test New Dimming Tests (if rated)

Note: each CB will determine

acceptance of older data

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Questions

THANK YOU

Jacki Swiernik Staff Engineer – Lighting

Intertek

jacki.swiernik@intertek.com www.intertek.com/lighting

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