USERS MAINTENANCE MANUAL

Download a copy of the manual here.

 

This user’s maintenance manual is provided to document the lighting fixtures, lamps and ballasts that have been replaced in this rail yard.  This identifies the types of new lights that have been installed throughout the facility to significantly improve the quality of light, provide more light in certain, defined areas, and reduce the cost of the energy used in lighting.

 

There are also some descriptions of the types of lighting technologies used and some simple troubleshooting steps to follow,

 

The lighting in the rail yard and buildings has been up-graded to more energy efficient lights that reduce the energy consumed while providing a higher quality light output.  Maintenance times and costs have been reduced by using longer life products and have higher lumen maintenance.  Appendix 1 lists the light fixtures and retrofit lamps and ballasts that were installed during this up-grade.  Warranty information is also provided.  All lighting products have a minimum 2 year, material replacement warranty.

 

Included here are trouble shooting techniques for the various products.

CAUTION: PLEASE OBSERVE APPROPRIATE ELECTRICAL SAFETY STEPS WHEN INSTALLING OR TROUBLESHOOTING ANY EQUIPMENT.

 

 

CERAMIC METAL HALIDE

The CMH lamps and electronic ballasts are used to retrofit HID lamps with magnetic ballasts.   Primarily, the fixtures best suited for CMH lamps are the high-masts, sportslighters, high-bays and flood lights that used Metal Halide or High Pressure Sodium lamps.  A 315 watt CMH lamp and 26 watt electronic ballast (341 total watts) are used to replace a 1000 watt HID or 750 watt Pulse Start Metal Halide and their magnetic ballast.  The 210 watt CMH lamp and 17 watt electronic ballast (227 total watts) are used to replace 400 watt HID, 320 watt Pulse Start Metal Halide and in some cases, 250 watt HID lamps with their respective magnetic ballasts.

 

The retrofit kits include the lamp, ballast, socket and bracket that matches the light center of the new lamp with the old lamp; this optimizes the reflector’s performance.

 

The CMH lamps are rated at 30,000 hrs. with a 2 year warranty and the ballast has a 5 year warranty.  Lumen maintenance is typically 96% light output after 8,000 hrs. life (about 2 years operation) and 90% light output after 12,000 hrs. life (about 3 years operation).

 

 Maintenance consists of replacing any defective lamps or ballasts using simple troubleshooting steps.

 

  1. Determine that proper power is being supplied to the fixture.
  2. If a photocell is controlling the operation of the fixture, determine that it is operating properly.
  3. Open the fixture and check all wire connections to insure none are loose.
  4. Replace the lamp. CAUTION:  DO NOT TOUCH GLASS PORTION OF LAMP WITH FINGERS.  USE GLOVES OR OTHER PROTECTIVE CLOTH.  Oil from fingers will damage glass when hot.  The lamps turn approximately 1/8 of a turn, counter clockwise to remove.

Insure pins on lamp are properly seated in socket and locked in place.

  1. If lamp does not light, replace ballast.   Match wiring wire color for wire color when replacing the ballast.   White, black and green for the input and red and blue for the output.  The remaining 2 wires on the output (grey and purple) are for a dimming circuit and should be capped off with wire nuts if not used.
  2. If new lamp operates, you may leave it in place or return original lamp to socket.
  3. If warranty period is in effect, return defective ballast and/or lamp to Southern Lighting Company for replacement credit.

 

 

INDUCTION LIGHTING

Induction lighting offers a significant energy savings and extended life over current HID products.  Induction products have the longest useful life of all technologies at present with a 100,000 hour life expectancy due to no cathodes required for operation.

 

Induction lighting is used as a retrofit of existing HID fixtures or in a complete, new fixture application.  Typical uses are replacing HID cobra head fixtures with new, 200 watt induction fixtures, new or retro-fitted flood lights (50 -200 watts), small flood lights (40 watts) for use in engine pits and an excellent replacement for high bay fixtures in car shops and engine shops (200 – 300 watts).  Both the induction lamp and ballast have a warranty period of five (5) years.

 

Troubleshooting is similar to that described above with Ceramic Metal Halide products, but in most cases, defective induction fixtures are usually ballast related.

 

Maintenance consists of replacing any defective lamps or ballasts using simple troubleshooting steps.

 

  1. Determine that proper power is being supplied to the fixture.
  2. If a photocell is controlling the operation of the fixture, determine that it is operating properly.
  3. Open the fixture and check all wire connections to insure none are loose.
  4. Check the output voltage of the ballast.  If there is no output, replace the ballast.   Match wiring wire color for wire color when replacing the ballast.   White, black and green for the input and two (2) small, white wires for the output to the lamp, connected through the small junction block with screw terminals. 
  5. If the lamp still does not operate, disassemble the fixture reflector to remove the induction lamp and install a new lamp.   Replacement lamps come with mounting brackets already installed on the lamp, so the new lamp is just screwed into the existing fixture body.
  6. Connect the two (2) small, white wires from the lamp to the junction block connecting to the ballast.
  7. If warranty period is in effect, return defective ballast and/or lamp to Southern Lighting Company for replacement credit.

 

LED Lighting

LED fixtures are becoming more prevalent in usage every day. LEDs offer excellent energy savings, extended life, up to 50,000 hours and a high quality light output.   Currently, LEDs are used in new flood light, wall pack and high-bay fixtures; there are no retrofit packages available and no trouble shooting is required as there is no customer access to the units. 

 

Many screw-in flood lights, PAR lamps and down-lights are now being replaced with LED lamps.   LED lamps are recommended over Compact Fluorescent Lamps due to the much longer life time, and equal to or better than energy savings.

 

FLUORESCENT LAMPS AND BALLASTS

The fluorescent retrofits include replacing any T12 lamp or magnetic ballast found with energy efficient T8 lamps and electronic ballast.   As an acceptable alternate, T5 lamps and ballasts may be used, primarily in high-bay applications. 

All T8, 4 ft. lamps are standardized at 28 watts energy usage and a bright white, 5000K color temperature - F28T8/850 is the correct designation.

SPARES

An appropriate amount of spare lamps and ballasts for all types of products used in the rail yard will be left with the managing department personnel for the lighting.  These spare items are listed in the attached list with easy reference numbers to identify them. 

Any questions can be sent directly to Southern Lighting Company, 866.551.5483 toll free,  919.772.5483 at our office or we can be contacted at frank@southernlightingcompany.com or bob@southernlightngcompany.com.  We will be glad to help you with any questions.