Fluorescent and HID duke it out

Both T5 high-output (HO) linear fluorescent and pulse-start metal halide HID lamps are excellent lighting options for high-bay applications in a variety of environments. In some installations, either lamp would be an excellent choice. In others, one lamp may provide greater benefits than the other. Each light source has several attractive attributes that might tip the scales toward one choice o...

10/15/2002


Key Concepts
 
  • T5 and HID can be used for high-bay applications.

  • Lighting choices should include potential energy and cost savings.

  • Compare advantages of both types before making a final decision.

Sections:
Ceiling heights
Fixture cost and installation
Lumen maintenance
Color rendering index
Relamping maintenance
Energy efficiencies
Restrike time
Daylight harvesting
Temperature
Personal preference
Sidebars:
Classifications for metal halide lamps


Both T5 high-output (HO) linear fluorescent and pulse-start metal halide HID lamps are excellent lighting options for high-bay applications in a variety of environments. In some installations, either lamp would be an excellent choice. In others, one lamp may provide greater benefits than the other. Each light source has several attractive attributes that might tip the scales toward one choice over another. Plant engineers involved in lamp and fixture selection can benefit from understanding the similarities and the differences between the two.

Historically, high-ceiling applications have been dominated by HID due to its high light output, energy efficiency, and extended life (Fig. 1). However, the new T5 HO lamps, with their smaller diameter, have greatly improved light output and compete well against HID in many high-bay applications.


Today, both technologies have evolved into very efficient lighting systems. T5 HOs are high-output versions of T5s that deliver up to 67% more light than the standard T5s (Fig 2). Additionally, T5 HOs deliver 95% lumen maintenance, a color rendering index (CRI) of 85, and instant starting. Pulse-start metal halide lamps, which use pulse-start ballasts, compare favorably to an earlier popular HID technology — switch-start metal halide lamps. The upgraded benefits include improved energy efficiency and lumen maintenance, faster warmup to full brightness, faster restrike time if power is interrupted when hot, and extended lamp life.


Both T5 HOs and pulse-start metal halide lamps are excellent choices for a lighting retrofit or a new lighting layout at a factory or warehouse. Key factors to consider when evaluating and comparing systems are:

  • Plant activity being lit

  • Total fixture cost (with lamps and ballasts)

  • Number of lamps required

  • Energy usage of each system

  • Lumen maintenance

  • Color rendering index

  • Ambient temperature

  • Ceiling height

  • Restrike time constraints.

    • Other considerations should include potential energy savings achievable through use of dimmers and motion sensors, as well as the practice of daylight harvesting (a conservation measure suitable for spaces with ample natural light), and aesthetic concerns.

      Ceiling heights

      A typical high-bay installation of between 25 and 45 ft calls for between 36,000 and 44,000 initial lumens, or 35-50 ft-candles, on the floor. If the lighting source is to be installed very high above the floor, from about 45 ft and up, pulse start is the best choice because of its high light output (see sidebar "Key cost and performance parameters" for a comparison). At this height, T5 HOs are not a feasible lighting solution because of the number of lamps needed to achieve similar foot-candles.

      However, at a lower height range of 20-35 ft, because of the inherent characteristics of T5 HOs (high lumen output and high lumen maintenance of fluorescents), they become a valid alternative.

      To achieve the target of 35-50 ft-candles at ground level, typically a pulse-start metal halide installation uses single high-bay fixtures (each with one lamp and one ballast) spaced throughout the plant. To achieve similar light levels, a T5 HO installation would have to use a fixture that requires four to six lamps and two or three ballasts, spaced throughout. This is because of the lower lumen output.

      Fixture cost and installation

      If the initial purchase and installation cost is a major factor, the advantage goes to pulse start. A pulse-start metal halide fixture, with one lamp and one ballast, is typically less expensive than a comparable T5 HO fixture requiring four to six lamps and multiple ballasts. Additionally, the T5 HO lamp and fixture technology is newer, therefore the systems tend to be more expensive. These costs will decrease with increased industry capacity and competition.

      Lumen maintenance

      Light output from all lamp types degrades, or dims, over time. In environments where the light level is critical, it is important to configure an application based upon the light level that will exist in the middle of the lamp life to ensure maintained light levels. Lumen maintenance (or design lumens) quantifies how well a lamp maintains the light output level at 40% of its rated life. Pulse-start metal halide lamps achieve a respectable 75% lumen maintenance; the T5 HOs achieve an excellent 95% lumen maintenance. In facilities where the falloff in light level could be critical, the T5 HO wins hands down. You get bright light longer, essentially achieving a close-to-constant light level throughout the life of the lamps.

      Color rendering index

      The CRI of lighting systems may sometimes be the deciding factor in a light source selection. For installations where true color under the lights is important, T5 HOs are recommended over pulse start because of their higher CRI (85 vs. 65). Furthermore, because T5s feature minimal color shift between lamps, they will provide uniformity among fixtures, one next to another, and also from one section of the plant to the next. However, in an industrial setting other factors normally take precedence over CRI.

      Relamping maintenance

      In terms of long-term maintenance cost, the two technologies share similar performance characteristics. For example, a 320-W pulse-start metal halide lamp, and 24, 39, and 54-W T5 HO lamps have 20,000 hr rated life.

      Good lamp maintenance practices for metal halide lamps include shutting them off once a week for 15 min. So, in facilities that operate continuously, the clear advantage goes to T5 Hos, since they do not require cycling.

      With respect to maintenance at the end of life, a T5 HO system having multiple lamps will provide light even when one lamp is out, while a one HID lamp system will leave a dark space when the lamp expires. However, if the HID lamp can readily be replaced from the ground with a pole, then the dark space is easily remedied. The T5 HOs require lifts for replacement.

      If a facility practices group relamping, then the scale tips toward the HID one-lamp source, since less labor is required per fixture.

      Energy efficiencies

      Both the pulse-start metal halide and T5 HO technologies have excellent energy efficiency. A pulse-start metal halide lamp delivers approximately 110 lumens/W, compared to 83-93 lumens/W for T5 HOs. However, using dimmers and sensors over a full range of control settings can reduce T5 HO energy consumption.

      Though the older 400-W metal halide lamps were somewhat less efficient than the T5 HOs, the 320-W pulse-start metal halide lamps have just about eliminated any advantage the T5 HOs may have held in that arena. However, the balance in any equation will shift in favor of T5 HOs if the plant can use a full range of dimmers and sensors to reduce energy consumption, because they work with dimmer controls over a full range of control settings. In contrast, metal halide lamps are limited to one or two stepdown settings.

      Restrike time

      Pulse start does not provide the "instant on" of a fluorescent system. Pulse-start metal halide systems typically warm up to 90% brightness within 2 min. and restrike for hot lamps within 4 min. In facilities where motion detectors can control turning the lights on, off, or to a preset dim level, the T5 HO offers greater dimming range than the stepdown dimming of pulse-start lamps, which dim the lamp to 50%.

      While stepdown dimming could be fine in a warehouse, it is not a good choice in an environment with constant or intermittent traffic. In a warehouse that uses motion or infrared sensors to detect people or machines moving down an aisle to pick materials or parts, the instant-start feature of T5 lamps is compatible, while the slower start of the metal halide lamps is not.

      Daylight harvesting

      In a plant that has the ability to use natural light, such as one with windows and/or skylights, a T5 HO system can take advantage of the practice of daylight harvesting to keep energy costs down. Daylight harvesting integrates electric light sources, light sensors, and dimmers with use of daylight through windows and skylights. As the natural light level within a space changes, the sensors perceive the differences and automatically regulate the dimmers to lower or raise electric light levels to maintain a constant light level within the environment. The more daylight can be used, the greater the energy and cost savings. If a plant can make use of natural light, the advantage goes to T5 HOs.

      Temperature

      T5 HO, like other fluorescent technology, is sensitive to both hot and cold temperatures, and has maximum light output at 35 C. Pulse start, however, operates equally well in a wide temperature range, and therefore has the advantage in hot or cold climates.

      Personal preference

      Aesthetics also could be a differentiator. One plant engineer might prefer the linear, more commercial ambiance that T5s provide, while another might favor the more industrial look of pulse-start metal halide.

      Edited by Jack Smith, Senior Editor, 630-288-8783, jsmith@reedbusiness.com

      More info

      The author is available to answer questions about this article. He can be reached at ted.simpson@philips.com

      Key cost and performance parameters

      Pulse Start MH T5 HO
      Fixture Cost+-
      Lamps Required+-
      Energy*eveneven
      CRI-+
      Lumen Maintenance-+
      Color Control-+
      Re-strike Time-+
      Use w/ Dimmers & Sensors-+
      Temperature Sensitive+-
      *Both Pulse-start metal halide and T5 HO have excellent energy efficiencies, however with the use of dimmers and sensors the T5 HO lamps have an energy advantage.


      Classifications for metal halide lamps

      Because metal halide lamps operate at high internal pressures, manufacturers provide explicit instructions and warnings to ensure proper use. Adherence to these instructions is critical to the safe operation of metal halide systems.

      Lamp manufacturers classify every metal halide lamp according to the recommended manner in which it should be used. The following are the three American National Standards Institute (ANSI) classifications:

      "E" types are to be used only in suitably rated enclosed fixtures in accordance with UL 1572 and CSA C22.2 No. 9.0 (UL 1598 and CSA C22.2 No. 250.0).

      "S" types may be used in open fixtures when operated in the specified near-vertical position. This category of lamps is limited to only certain lamps in the 350 to 1000-W range.

      "O" types comply with ANSI Standard C78.387 for containment testing and may be used in open fixtures.

      For more information on best practices for metal halide lighting systems and FAQs about ruptures in metal halide lighting systems visit the NEMA website (



The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Pipe fabrication and IIoT; 2017 Product of the Year finalists
The future of electrical safety; Four keys to RPM success; Picking the right weld fume option
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Power system design for high-performance buildings; mitigating arc flash hazards
VFDs improving motion control applications; Powering automation and IIoT wirelessly; Connecting the dots
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me