How to Troubleshoot Issues With Industrial Lighting Systems

Introduction

Industrial lighting systems provide illumination in warehouses, factories, and other commercial spaces. However, like any electrical system, issues can arise that affect lighting performance. As a facility manager, it's important to understand common industrial lighting problems and how to systematically troubleshoot them. Proper lighting is essential for worker safety and productivity. This guide will provide an in-depth overview of troubleshooting industrial lighting systems.

Common Issues With Industrial Lighting

There are several common issues that can occur with industrial lighting systems:

Fixture Outages

Having individual light fixtures suddenly go dark is a frequent problem. This is often caused by burned out bulbs, loose wiring connections, or faulty ballasts. Systematically checking each component can help pinpoint the root cause.

Flickering Lights

If lights flicker erratically, the problem is likely a loose connection, faulty component, voltage fluctuation, or compatibility issue between the bulbs and ballasts. Flickering needs to be addressed promptly since it can indicate an electrical issue and creates an annoying distraction.

Dimming or Insufficient Light Levels

Light levels that are too low can have several causes. Old bulbs may have reached the end of their lifespan. Buildup of dust on fixtures and old bulbs reduces light output. Voltage problems like drops or spikes can also lead to lower illumination.

Buzzing from Fixtures

An audible buzzing or humming is usually caused by a faulty ballast or bad electrical component. This noise indicates that repairs are needed. Allowing buzzing fixtures to operate will likely result in premature failure.

Groups of Lights Out

When banks of fixtures in part of a facility all go out at once, the issue may involve the circuit breakers, fuses, or wiring to that section. Any outage affecting multiple lights should be investigated right away.

Steps for Troubleshooting Industrial Lighting

Systematically isolating issues affecting your industrial lighting involves following some general troubleshooting best practices:

Inspect the Lighting Circuitry

Check breaker panels for any tripped breakers affecting lights. Also verify that applicable fuses are intact and have continuity. Examine wiring connections for signs of loose, damaged, or burnt wires.

Check for Faulty Components

Remove covers and inspect ballasts, capacitors, ignitors, and other lighting components for signs of damage. Replace any questionable parts. Also check that all wiring connections are tight.

Verify Voltage Input

Use a voltmeter to check the voltage at the lighting circuit. Input voltage should match fixture specifications. Low voltage can cause dimming and other issues. High voltage reduces bulb and ballast life.

Rule Out Faulty Bulbs

Systematically replace bulbs with known good ones. Inspect the old bulbs for broken filaments or end-of-life darkening at the bulb ends. Replace in sets so color temperature remains consistent.

Evaluate Light Levels and Uniformity

Use a light meter to check illuminance levels in different areas. Readings should meet standards for the workspace. Uneven light distribution can indicate problems.

Isolate the Problem Source

If issues are isolated to specific fixtures, focus troubleshooting there. If multiple zones are affected, check main feeds and circuit components. Narrow down the issue before replacing components.

Test Repairs and Replace Components

After repairs and replacements, power up the system and verify normal operation. Replace components one at a time until problems are resolved. Retest repaired areas before restoring full power.

Follow Manufacturers' Guidance

Consult installation and maintenance instructions provided by the lighting manufacturer when possible. Follow prescribed repair procedures and use factory authorized replacement parts.

Preventive Industrial Lighting Maintenance

Along with troubleshooting issues as they arise, some key maintenance practices can help minimize problems:

• Clean fixtures regularly to remove dust buildup and maintain light levels.

• Periodically check wiring connections for tightness.

• Replace aging ballasts and capacitors proactively before failure.

• Upgrade to LED fixtures which have very long lifespans.

• Group bulbs by installation date and replace in batches at rated lifespan.

• Keep spare parts like ballasts, LED drivers, and bulbs on hand.

• Have qualified electricians handle any major repairs and comply with codes.

When to Call a Professional

While many lighting issues can be addressed in-house, some scenarios require calling in a lighting contractor or electrician:

• If problem cause cannot be found through standard troubleshooting.

• Repairing or replacing ceiling-mounted or hard to access fixtures.

• Wiring and electrical issues like shorts, faulty breakers, and voltage problems.

• Major lighting outages over a wide area.

• Upgrading or redesigning lighting systems.

• Integration, programming and controls issues.

Knowing when to seek outside expertise can minimize safety risks, avoid costly mistakes, and speed resolution of tricky lighting problems.

Conclusion

Keeping industrial lighting performing optimally requires diligently monitoring the system and promptly addressing any issues that arise. Following a structured troubleshooting process can systematically isolate problems. Combining repairs with preventive maintenance helps minimize lighting breakdowns and create a brighter, more productive facility. When major issues arise, don't hesitate to enlist lighting professionals to resolve stubborn problems.