U.S. patent application number 09/742461 was filed with the patent office on 2001-11-29 for diagnostic tester for multi-ballast lighting fixture.
Invention is credited to Belman, Russel L., Spink, Kenneth M., Tury, Edward L., Van Deusen, Gary.
Application Number | 20010045833 09/742461 |
Document ID | / |
Family ID | 27007314 |
Filed Date | 2001-11-29 |
United States Patent
Application |
20010045833 |
Kind Code |
A1 |
Tury, Edward L. ; et
al. |
November 29, 2001 |
Diagnostic tester for multi-ballast lighting fixture
Abstract
A diagnostic testing system for use with two or more lighting
systems of the HID sports lighting type, wherein two or more
lighting systems have their ballasts and diagnostic receptacles
combined in a single ballast box at the base of a light pole for
diagnostic access. Each lighting system has its own diagnostic
receptacle electrically coupled to the other lighting system
through a common block supplying power to the multi-system fixture.
Each lighting system typically comprises at least one lamp, a
ballast, a capacitor, and wiring interconnecting the lamp, ballast,
and capacitor. Each diagnostic receptacle includes a continuity
plug wired to maintain electrical connection to the common block
while it is plugged in, and to cause its associated lighting system
to be electrically isolated from the common block when the plug is
removed. The diagnostic receptacles are adapted to receive a
connector from a handheld diagnostic tester which maintains the
electrical isolation from the common block during the diagnostic
testing.
Inventors: |
Tury, Edward L.; (Brighton,
MI) ; Spink, Kenneth M.; (Jerome, MI) ;
Belman, Russel L.; (North Adams, MI) ; Van Deusen,
Gary; (Hillsdale, MI) |
Correspondence
Address: |
THOMAS N. YOUNG
Suite 624
3001 West Big Beaver Road
Troy
MI
48084-3107
US
|
Family ID: |
27007314 |
Appl. No.: |
09/742461 |
Filed: |
December 20, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09742461 |
Dec 20, 2000 |
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09376111 |
Aug 13, 1999 |
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09376111 |
Aug 13, 1999 |
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08633079 |
Apr 16, 1996 |
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6087834 |
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Current U.S.
Class: |
324/508 |
Current CPC
Class: |
H05B 47/20 20200101;
G01R 31/44 20130101; H05B 47/26 20200101 |
Class at
Publication: |
324/508 |
International
Class: |
G01R 031/00 |
Claims
Accordingly, we claim:
1. A diagnostic receptacle system for use with a handheld
diagnostic tester and at least two lighting systems sharing a
ballast box on a light fixture, each lighting system comprising at
least one lamp, a ballast, a capacitor, and a plurality of wires
interconnecting the lamp, the ballast, and the capacitor, the
diagnostic receptacle system comprising: a first diagnostic
receptacle associated with a first lighting system, and a second
diagnostic receptacle associated with a second lighting system,
each diagnostic receptacle being electrically connected to each of
the lamp, the ballast, and the capacitor in its associated lighting
system, each diagnostic receptacle being adapted to receive a
connector from a hand held diagnostic tester capable of
individually testing operability of the lamp, the ballast, the
capacitor, and the plurality of wires interconnecting them, the
first and second diagnostic receptacles further being electrically
connected to a common block in the ballast box; first and second
continuity plugs mated with the first and second diagnostic
receptacles, respectively, each continuity plug comprising a
plurality of pins adapted to be inserted in mating terminals in the
diagnostic receptacles, the plurality of pins in the continuity
plugs being electrically connected in pairs to define continuity
paths for the lamp, ballast, capacitor, plurality of wires, and
common block when the continuity plug is mated with the diagnostic
receptacle; wherein, the first diagnostic receptacle is
electrically isolated from the common block when the first
continuity plug is removed from the first diagnostic receptacle,
and the second diagnostic receptacle is electrically isolated from
the common block when the second continuity plug is removed from
the second diagnostic receptacle.
2. The diagnostic receptacle system of claim 1, further including a
diagnostic tester matable with the first and second diagnostic
receptacles in a manner maintaining the electrical isolation of the
first and second diagnostic receptacles from the common block
during diagnostic testing.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus and method for
testing the electrical components and wiring contained in a
lighting system.
BACKGROUND OF THE INVENTION
[0002] Lighting systems used to illuminate athletic fields such as
baseball fields, football fields, soccer fields and the like
generally require the installation of light fixtures 20-120 feet
above the ground. The light fixtures are often installed in arrays
mounted at the top of a support pole. If any light fixture in a
lighting array malfunctions, it may be difficult to determine the
source of the failure without the use of a crane or ladder capable
of reaching the light fixtures.
[0003] Lighting systems which use high intensity discharge (HID)
lamps require the use of ballasts, capacitors, and various wires
interconnecting the components of the lighting system. The failure
of a lamp, ballast, capacitor, or wire may result in the failure of
the lighting system.
[0004] Current test methods involve disconnecting each component to
test them individually or swapping each component in and out of the
lighting system to locate any defective components. This procedure
requires electrical power to be applied to the system, and/or the
use of special meters and the technical specifications for each
component in order to determine the operability of each component.
Furthermore, these tests may isolate problems in a particular
component, but cannot detect problems in the wiring between the
components without the use of a crane or boom truck to reach the
light fixtures at the top of the pole.
[0005] Therefore, these previous attempts to locate faults in
lighting systems are expensive, time-consuming, and must be
performed by an electrician due to the requirement of a live power
test. Additionally, the testing of HID lighting systems requires a
specialized knowledge not held by all electricians. Thus, previous
diagnostic testing systems and methods required a qualified
electrician possessing the appropriate knowledge and special meters
to test HID lighting systems.
SUMMARY OF THE INVENTION
[0006] The present diagnostic tester provides an apparatus for
testing a lighting system having at least one lamp, a capacitor, a
ballast, and various wires interconnecting these lighting system
components. The diagnostic tester is capable of isolating the
particular component or wiring in the lighting system producing the
failure of the lamp, including failure of the lamp itself. The
diagnostic tester connects to a diagnostic receptacle on a light
pole easily accessible from the ground, rather than by a crane. The
tests are performed with the lighting system power turned off and
therefore may be performed by maintenance personnel, rather than an
electrician. Since the power is off, the risk of injury due to
electric shock is eliminated.
[0007] The components of the lighting system are not disconnected
to perform the test, thereby making the testing easier, faster, and
less expensive. Since the testing is performed at or near ground
level, the use of a crane or similar apparatus is not required.
Therefore, maintenance costs are reduced by permitting the quick
identification of problem components. Additionally, the diagnostic
tester permits the pretesting of light fixtures on the ground
before installation on the lighting poles.
[0008] The diagnostic tester includes a connector adapted to
operatively engage the diagnostic receptacle. Means are provided in
the diagnostic tester for automatically and simultaneously testing
the ballast, the capacitor, and the plurality of wires contained in
the lighting system which connect the capacitor and the ballast to
a single lamp.
[0009] A multivibrator circuit connected to any illuminatible
device is used to test the capacitor and the illuminatible device
blinks if the capacitor is functioning properly. A ballast test
circuit includes an illuminatible device, such as a light emitting
diode, and a driver for indicating whether the primary and the
secondary of the ballast is functioning properly. A wiring test
circuit includes at least a pair of light emitting diodes, and
possibly an optional LED, along which associated drivers for
indicating whether the plurality of wires in the lighting system
connected between the ballast and the lamp are properly
connected.
[0010] A continuity plug is capable of being inserted into the
diagnostic receptacle when the diagnostic tester is disconnected
from the diagnostic receptacle. The continuity plug, when inserted
into the diagnostic receptacle, interconnects the lamp wiring, the
ballast and the capacitor in a normal operable manner for normal
operation of the lighting system.
[0011] When testing the lighting system, power is first
disconnected from the lighting system. The LED's in the tester are
then tested for proper operation. Next, the continuity plug is
removed from the diagnostic receptacle and the diagnostic tester is
connected to the receptacle. The capacitor is tested and its
associated light emitting diode indicates whether the capacitor is
functioning properly. Similar tests are performed on the ballast
and wiring contained in the lighting system.
[0012] One of the LEDs in the tester may also be employed for
indicating the continuity of a lighting system fuse. In this
optional embodiment, a pair of terminals are mounted on the tester
housing and are engageable with opposite ends of a lighting system
fuse. The terminals are connected across the indicator such that
the application of electrical power to the indicator and the
terminals will enable the indicator to indicate the continuity or
non-continuity of a fuse connected across the terminals by the on
or off state of the indicator.
[0013] In another embodiment in which a lighting system employs a
higher wattage lamp which requires the use of a separate ignitor,
the diagnostic tester of the present invention may also be employed
to test the ignitor by employing the same lighting wiring test
procedures described herein.
[0014] After all tests have been performed, the diagnostic tester
is disconnected from the diagnostic receptacle and the continuity
plug is reinserted into the diagnostic receptacle. Finally, power
is restored to the lighting system.
[0015] It is becoming increasingly common to mount two or more
lighting systems on a single pole with the lighting systems (lamp,
capacitor, ballast, and various wires interconnecting them) sharing
a single ballast box. Power is often supplied to these dual-system,
single ballast box fixtures via a "common block" power and fusing
terminal. In a further form of the invention, a dual-system ballast
box having a "common block" is provided with two diagnostic
receptacles. Each diagnostic receptacle is electrically
interconnected with the common block and one lighting system's
lamp, capacitor, ballast, and wiring through a special continuity
plug. The manner in which each diagnostic receptacle is wired into
its respective lighting system and the common block through the
continuity plug provides an automatic isolation of the system from
the common block when the continuity plug is removed for testing.
This isolation prevents the possibility of backfeed from the other
ballast sharing the common block. Backfeed from the untested
ballast can result in a false reading with respect to a particular
component or wiring in the system being tested.
[0016] This dual-system, single-box diagnostic receptacle
arrangement is tested with a diagnostic tester and connector
modified from the single-system receptacle described above. The
continuity plug for each dual system receptacle also differs from
the single-system plug, and provides automatic isolation of an
associated lighting system from the common block.
[0017] The dual-system receptacles are also useful for high wattage
systems which may include extra capacitor and lamp wire connections
in the ballast.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The various features, advantages and other uses of the
present invention will become more apparent by referring to the
following description and drawings in which:
[0019] FIG. 1 is a perspective view of a diagnostic tester and
diagnostic receptacle according to the present invention;
[0020] FIG. 2 is a block diagram illustrating the interconnection
of the diagnostic receptacle with various components of a lighting
system;
[0021] FIG. 3 is a schematic diagram showing a continuity plug as
used with the present invention and its electrical connections;
[0022] FIG. 4 is a schematic diagram of the inventive diagnostic
tester and the lighting system components being tested;
[0023] FIG. 5 is a flow chart describing the overall procedure used
when testing a lighting system according to the present
invention;
[0024] FIG. 6 is a flow chart describing the procedure followed to
determine which component or components of the lighting system are
malfunctioning;
[0025] FIG. 7 is a pictorial representation of a modification to
the diagnostic tester of the present invention according to an
alternate embodiment of the present invention;
[0026] FIG. 8 is a partial schematic representation showing a
modification to the schematic of FIG. 4 for use in conjunction with
the modification depicted in FIG. 7;
[0027] FIG. 9 is a schematic diagram of an alternate light system
circuit which can be tested by the diagnostic tester of the present
invention;
[0028] FIG. 10 is a schematic representation of a dual-system
ballast and diagnostic receptacle arrangement, wherein two lighting
systems, each with its own ballast, capacitor, lamp and wiring, are
provided with diagnostic receptacles contained in a single ballast
box having a common block for power supply and fusing;
[0029] FIG. 10A is a schematic representation of the wiring of a
continuity plug for the lefthand ballast and diagnostic receptacle
in FIG. 10;
[0030] FIG. 10B is a schematic representation of the wiring of a
continuity plug for the righthand ballast and diagnostic receptacle
of FIG. 10;
[0031] FIG. 11 is a schematic representation of a dual-system
ballast and diagnostic receptacle arrangement, similar to that of
FIG. 10 but arranged to test a higher wattage fixture in which the
ballast is provided with an additional capacitor and lamp
connection;
[0032] FIG. 11A is a schematic representation of the wiring of a
continuity plug for the lefthand diagnostic receptacle of FIG.
11;
[0033] FIG. 11B is a schematic representation of the continuity
plug wiring for the righthand diagnostic receptacle of FIG. 11;
[0034] FIG. 12 is a perspective view of a dual-system ballast box
containing two diagnostic receptacles according to the present
invention, and a diagnostic tester according to the present
invention plugged into one of the diagnostic receptacles in the
ballast box;
[0035] FIG. 13 is a plan view of the pin terminals of the multi-pin
diagnostic receptacle of FIG. 12, useful for the embodiments of
FIGS. 10 and 11;
[0036] FIG. 14 is a close up view of the display panel of the
diagnostic tester of FIG. 12;
[0037] FIG. 14A is a schematic diagram of the diagnostic tester of
FIG. 14;
[0038] FIG. 14B is a table showing the connections between the
circuit board pins of the diagnostic tester of FIG. 14A and the
connector of the tester;
[0039] FIG. 15 is an enlarged view of the righthand lighting system
of FIG. 10; and
[0040] FIG. 16 is an enlarged view of the righthand lighting system
of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] Referring to FIG. 1, a diagnostic tester 10 according to the
present invention is illustrated. Diagnostic tester 10 includes a
housing 14 which contains the circuitry and components of the
tester 10. A push button switch 16 is used to activate the
diagnostic tester 10 as described hereinafter.
[0042] A cable 18 extends from diagnostic tester 10 and has a male
connector 20 at its terminal end. A ballast box 12, which forms
part of the lighting system to be tested and is typically mounted a
short distance; i.e., 10 feet, above grade on a light pole,
includes a female multi-pin diagnostic receptacle 22. Receptacle 22
is mounted within ballast box 12 and is electrically connected to
the various components of the lighting system. Preferably, male
connector 20 is a plug-in, quick-release connector which is
designed to mate with diagnostic receptacle 22. However, any other
type of connector may be employed in the present diagnostic tester
10.
[0043] Diagnostic receptacle 22 may be installed in ballast box 12
at the time of manufacture, or may be retrofitted into an existing
ballast box already installed in a lighting system. To retrofit
receptacle 22 to an existing ballast box, the receptacle 22 is
connected as described below with reference to FIG. 2. A complete
lighting installation may include several ballast boxes, with each
ballast box having a diagnostic receptacle for each ballast
therein.
[0044] Diagnostic tester 10 is a small hand-held device capable of
being carried easily from one test location to another. Tester 10
has an internal power source and performs the tests automatically,
thereby requiring only minimal interaction by the operator.
[0045] Separate illuminatible devices, such as light emitting
diodes, (LED's 24, 26, 28, 30, and 32) are used to indicate whether
various components of the lighting system are functioning properly
LED 29 is optional, as described hereafter. The function of each
LED will be described below with reference to the schematic diagram
illustrated in FIG. 4. Although the present invention is described
as utilizing light emitting diodes, it will be understood by those
skilled in the art that various other types of indicator and
illuminatible devices may be used to indicate proper component
operation. Such other devices include various types of lights,
meters, or display panels.
[0046] FIG. 2 illustrates a block diagram of the various components
in the lighting system and their electrical interconnection with
each other and with diagnostic receptacle 22. Receptacle 22 is
shown having a plurality of electrical connection points
representing a plurality of electrical pins in the receptacle 22. A
ballast 33 is connected to pin 7 of diagnostic receptacle 22.
Additionally, ballast 33 is connected to a lamp 40, and a negative
line fuse 46. A capacitor 34 has a first terminal 36 and a second
terminal 38. First capacitor terminal 36 is connected to pin 2 of
diagnostic receptacle 22, and second capacitor terminal 38 is
connected to pin 1 of the diagnostic receptacle. An HID lamp 40 is
mounted in lamp socket 42 which is connected to ballast 33 and pin
6 of diagnostic receptacle 22. An optional resistor 43 is connected
across the leads of the socket 42. A positive line fuse 44 is
connected to pin 4 of diagnostic receptacle 22. Negative line fuse
46 is connected to ballast 33 as well as pin 3 of diagnostic
receptacle 22.
[0047] When the diagnostic tester 10 is not attached to diagnostic
receptacle 22, a continuity plug 48 is mated with the diagnostic
receptacle 22. FIG. 3 illustrates the electrical connections
contained within continuity plug 48. The pin numbers illustrated in
FIG. 3 correspond with and electrically connect with the pin
numbers illustrated in FIG. 2 with respect to diagnostic receptacle
22. In particular, pins 4 and 5 are shorted together, thereby
directing power from positive line fuse 44 directly to ballast 33.
Additionally, pins 7 and 2 are shorted together, thus connecting
the first capacitor terminal 36 to ballast 33. Finally, pins 1 and
6 are shorted together, thereby connecting second capacitor
terminal 38 to lamp socket 42. Therefore, when continuity plug 48
is mated with diagnostic receptacle 22, the lighting system
operates in a normal manner.
[0048] FIG. 4 illustrates a schematic diagram of the diagnostic
tester 10 circuit as well as the lighting system components being
tested. The left side of the schematic illustrated in FIG. 4
represents the components of the lighting system, and resembles the
connections illustrated in FIG. 2. Capacitor 34 is connected
between pins 1 and 2 of diagnostic receptacle 22. Pin 4 of
diagnostic receptacle 22 is connected to positive line fuse 44, and
pin 8 of the diagnostic receptacle is connected to ground. Pins 3,
5, and 7 are connected to ballast 33, while pins 6 and 3 are
connected to lamp 40.
[0049] Male connector 20 on diagnostic tester 10 is a multi-pin
connector which mates with diagnostic receptacle 22. Preferably,
connector 20 is a quick-release connector for simple connection
with receptacle 22.
[0050] A 9-volt battery 50 is connected between ground and switch
16, thereby providing power (indicated by signal VBAT) to the
tester circuit when the switch 16 is depressed. The various
illuminatible devices or LED's 24, 26, 28, 29, 30 and 32 are biased
by their respective drive transistors to a conductive state when
VBAT power is applied thereto and the connector 20 is disconnected
from the connector 22 on the receptacle 12. This provides a check
of the operability of each LED.
[0051] Pins 1 and 2 of connector 20 connect with capacitor
terminals 36 and 38. The circuit formed by NAND gates 52 and 54 as
well as resistors 56, 58 creates a multi-vibrator circuit with
capacitor 34. When capacitor 34 is connected and functioning
properly, the multi-vibrator circuit oscillates, thereby causing
transistor 60 to turn on and off and causing LED 28 to blink. If
LED 28 does not blink, then the capacitor 34 is either defective or
improperly connected. The rate at which LED 28 blinks is a function
of the capacitance of capacitor 34. The greater the capacitance of
capacitor 34, the slower LED 28 blinks. If LED 28 blinks extremely
fast, capacitor 34 may be defective; i.e., the capacitor 34 may
have a reduced capacitance.
[0052] The ballast continuity is tested using pins 5 and 7 of
connector 20. The circuit connected to pin 5 of connector 20 tests
the ballast primary. If the ballast primary is functioning
properly, a base current is conducted to transistor 62, connecting
the remainder of the circuit to ground. Therefore, the base of
transistor 64 is connected to ground, thereby extinguishing LED 30.
Therefore, if LED 30 is illuminated, the ballast primary is
malfunctioning, i.e., an open circuit.
[0053] Pin 7 of connector 20 is connected through a resistor to the
base of transistor 68, which receives a base current from the
ballast secondary. If a base current is present, transistor 68
connects the remainder of the circuit to ground, thereby
extinguishing LED 32. An illuminated LED 32 indicates a
malfunctioning ballast secondary.
[0054] The lamp 40 wiring extends from the ballast 33 and the
receptacle 22 up along a light pole, not shown, to a junction
connection with leads to the socket 42 in the light fixture.
[0055] If the lamp wiring is not connected properly, i.e., open at
the socket 42, transistor 76 will conduct through optional resistor
43, thereby causing transistor 78 to conduct. The activation of
transistor 78 causes signal VBAT to be applied to the inputs of
NAND gates 80 and 82. Since the inputs of NAND gates 80 and 82 are
wired together as inverters, a logic Hi signal is applied to the
NAND gate inputs thereby generating a logic LO signal at the output
and extinguishing optional LED 29. Therefore, if LED 29 is off, a
lamp socket wiring continuity fault is indicated. Conversely, if
LED 29 is illuminated, proper lamp socket wiring is present.
[0056] In the preferred form, an HC4011 integrated circuit is used
to provide the four NAND gates 52, 54, 80, and 82. The two inputs
of each NAND gate are electrically connected together, thereby
causing each NAND gate to operate as an inverter.
[0057] As shown in FIG. 4, the positive power lead is connected
through transistor 76 and LED's 24 and 26 to ground. A fuse 74 is
connected to pin 3 of the connector 20 and to the junction of LED's
24 and 26. LED 26 is connected through fuse 72 to ground in the
receptacle 22. Thus, LED 24 will be illuminated if the positive
lamp wiring is properly connected; but when not illuminated, a
short to the negative lead is present. Similarly, LED 26 will be
illuminated if the negative lamp wiring is properly connected. When
LED 26 is not illuminated a short of the negative wiring to ground
is indicated. If both LED's 24 and 26 are not illuminated at the
same time during a test, a short of the positive wiring to ground
is present.
[0058] In operation, the lighting system is tested with the main
power off, as shown in FIG. 5 at step 100. At step 102, before the
tester 10 is connected to the receptacle 22, switch 16 is depressed
to test the operability of all of the LED's in the tester 10 by
applying power to each LED to cause illumination of each operable
LED. Next, continuity plug 48 is removed from diagnostic receptacle
22 at step 104. Next, at step 106, the diagnostic tester 10 is
connected to diagnostic receptacle 22, causing all diagnostic tests
to be performed automatically at step 108.
[0059] Depending on the lighting system components which do not
pass the diagnostic tests, one or more LED's on the diagnostic
tester will indicate a faulty component or faulty wiring by an "on"
or "off" state as described above and as shown in FIG. 1 on the
face of the tester 10. If the diagnostic tester 10 indicates that
all tests have passed, but one or more lamps in the lighting system
are not functioning properly, this indicates that the lamp is at
fault. Thus, the tester 10 determines a lamp fault by process of
elimination; i.e., if all other components and wiring are
functioning properly, then the lamp must be the defective
component.
[0060] At step 110, the defective component or components are
replaced or repaired. At step 112, the diagnostic tester 10 is
removed from diagnostic receptacle 22, and continuity plug 48 is
reinserted into the diagnostic receptacle at step 114. Finally, at
step 118, main power to the light fixtures in the lighting system
is turned on.
[0061] FIG. 6 is a flow chart which illustrates the procedure
followed to determine which component or components of the lighting
system are malfunctioning. In FIG. 6, step 120 corresponds to step
106 in FIG. 5. Similarly, step 146 corresponds to step 112 in FIG.
5. Steps 122-144 are an expanded depiction of steps 108 and 110 in
FIG. 5. At step 120, which corresponds to step 106 in FIG. 5, the
diagnostic tester 10 is connected to the diagnostic receptacle 22.
Step 122 tests the lamp wiring, step 124 tests the capacitor, step
126 tests the ballast primary, and step 128 tests the ballast
secondary. Although steps 122-128 are illustrated as four separate
steps, these tests are performed simultaneously by the diagnostic
tester 10. As shown in FIG. 4, separate test circuits are provided
to test each component of the system, thereby permitting
simultaneous testing of the lighting components. The results of all
diagnostic tests are indicated by the LED's on the diagnostic
tester 10.
[0062] At step 130 the operator determines whether the lamp wiring
test passed by observing LED's 24, 26 and/or optional LED 29. If
LED 24 is illuminated or "on" the positive wire is properly
connected. However, an off or not illuminated state for LED 24
indicates that the lamp positive wire is shorted to the negative
wire. LED 26 provides a similar indication of the operability of
the negative lamp wire, but with an off state indicating a short to
ground. An "off" or non-illuminated state of both LED's 24 and 26
indicates that both that the positive wire is shorted to ground. If
LED 29 is illuminated or on, then the lamp socket leads have
continuity. If LED 29 is not illuminated, then there is a fault in
the lamp leads at the lamp socket. If any part of the lamp wiring
test did not pass, then the lamp wiring is repaired at step 132,
and the testing procedure is completed at step 146 by removing the
diagnostic tester 10 from the diagnostic receptacle 22. If the lamp
wiring test passed at step 130, then the operator next determines
whether the capacitor test passed at step 134.
[0063] If the capacitor 34 is functioning properly, LED 28 blinks
on and off. If LED 28 does not blink, or blinks extremely fast,
then the capacitor 34 is faulty. If the capacitor test did not
pass, then the capacitor 34 is replaced at step 136, and the
testing is completed at step 146.
[0064] If the capacitor test passed at step 134, then the operator
next determines whether the ballast primary test passed at step
138. LED 30 is off if the ballast primary is functioning properly.
If LED 30 is illuminated, then the ballast primary is open. If the
ballast primary test failed, the ballast 33 is replaced at step
140.
[0065] If the ballast primary test passed, then the user next
determines whether the ballast secondary test passed at step 142.
If LED 32 is off, then the ballast secondary is functioning
properly. An illuminated LED 32 indicates that a fault exists in
the ballast secondary. If the ballast secondary test failed, then
the ballast 33 is replaced at step 140, and the lighting tests are
completed.
[0066] If the ballast secondary test passed, and the lighting
system is still inoperative, then the lamp 40 is replaced at step
144, and the testing is completed at step 146. Thus, the lamp 40 is
tested by process of elimination. As shown in FIG. 6, the wiring,
capacitor, ballast primary, and ballast secondary are tested first
to determine proper operation. If any one or more of these
components fail their respective test, then that particular
component is repaired or replaced. If a lighting system is not
functioning properly, but all four of the above-mentioned tests
passed, the lamp 40 is determined to be at fault and is replaced.
Therefore, if the lighting system is not working and all components
except the lamp 40 are functioning properly, the lamp 40 must be
the malfunctioning component in the lighting system.
[0067] Once the diagnostic tester 16 is connected to the diagnostic
receptacle, the diagnostic tester 10 performs all tests
automatically and simultaneously. The diagnostic tester 10 does not
require any user input or user intervention, other than determining
the status of the various LED's in the diagnostic tester 10 during
testing.
[0068] It should also be noted that even though the present
diagnostic tester 10 has been described as simultaneously testing
each of the ballast 33, the capacitor 34 and the lamp wiring, the
diagnostic tester 10 can also be constructed to test any one or two
of these components.
[0069] The diagnostic tester 10 of the present invention may also
be modified to perform additional tests. As shown in FIGS. 7 and 8,
the diagnostic tester 10 may be used to test the continuity of the
fuses 44 and 46 used in the lighting system circuit. As is
conventional, such fuses 44 and 46 are typically of the "midget"
type and have two opposed conductive end caps or contacts. As shown
in FIG. 7, a pair of terminals 81 and 83 are mounted on the housing
of the diagnostic tester 10 at any convenient location. Thus,
although the pair of terminals 81 and 83 are shown as being mounted
on the top of the housing, it will be understood that the pair of
terminals 81 and 83 may also be mounted on the bottom or any other
surface of the housing. The terminals 81 and 83 are connected
across the optional indicator or LED 29 as shown in FIG. 8.
[0070] In use, the terminals 81 and 83 are engaged with opposite
conductive ends of a fuse 44 or 46. The "push-to-test" push button
16 is then depressed to supply power to the transistors 76 and 78,
shown in FIG. 4, and to the NAND gates 80 and 82 shown in FIGS. 4
and 8. If the fuse connected across the terminals 81 and 83 has
continuity, the LED 29 will be in a non-illuminated state. However,
if the fuse is defective or open, the LED 29 will be illuminated
thereby providing indication of a defective fuse. It should be
noted that the fuse test is conducted while the connector 18 is
disconnected from the ballast box 12.
[0071] The diagnostic tester 10 may also be used to detect the
operability of an ignitor 90 shown in FIG. 9 which is used with a
higher wattage lamp 40', such as a 2000 watt lamp. Such a higher
wattage lamp will require a capacitor 34 and a higher wattage
ballast 33 which are interconnected with fuses 44 and 46 as shown
in FIG. 9. It will also be understood that a second series
connected ballast 33 and capacitor 34 may be connected in parallel
with the ballast 33 and capacitor 34 shown in FIG. 9.
[0072] As the leads of the lamp 40' are connected to the lamp post
and common terminals of the ignitor 90, the diagnostic tester 10
can also test the operability of the ignitor 90 in the same manner
as the test described above for testing proper wiring of the lamp
leads. The lamp socket connections are connected to the connector
pins 3 and 6 as shown in FIG. 4 and can provide an indication of
the operability or non-operability of the ignitor 90 by performing
the same lamp wiring test described above. Thus, if the ignitor has
failed, typically by shorting to ground, the lamp connection will
be open causing transistors 76 and 78 to conduct as shown in FIG. 4
and described above. Conduction of transistor 78 through the NAND
gates 80 and 82 causes the optional LED 29 to remain off when a
continuity fault is present or to remain illuminated when proper
ignitor 90 operation is detected.
[0073] Referring now to FIGS. 10-16, an embodiment of the invention
is disclosed for diagnostic testing of multiple lighting systems
installed on a single pole, and in particular for situations where
two or more ballasts are contained in a single ballast box and
share a "common block" for power supply and fusing in a manner
which is known to those skilled in the art.
[0074] Referring first to FIG. 10, a first embodiment of a
multiple-system diagnostic receptacle arrangement according to the
invention is illustrated for a lower-wattage, "single ended" lamp
fixture in which two lighting systems, each with its own lamp,
ballast, capacitor and wiring, share a power supply through a
common block and have their ballasts and diagnostic receptacles
contained in a single ballast box on a light pole. FIGS. 10, 10A
and 10B schematically represent the wiring for the two lighting
systems, their respective diagnostic receptacles, and their
continuity plugs.
[0075] Each lighting system in FIG. 10 is similar to that shown in
FIG. 2, comprising an HID lamp 200, a ballast 210, one or more
capacitors 220, a power supply 230, fuse 240 connected to the "hot"
power wire, a multi-pin diagnostic receptacle 250, and a mating
continuity plug 260. Each system is grounded at 270.
[0076] Unlike the lighting system in FIG. 2, the two lighting
systems in FIG. 10 share both a ballast box and their power supply
through a common block at 230. Use of the common block simplifies
the main power disconnect and fusing for the lighting systems.
[0077] In the illustrated embodiment of FIG. 10, diagnostic
receptacles 250 and their continuity plugs 260 are twelve-pin
receptacles and plugs. This requires modification to the diagnostic
tester 10 and its nine-pin connector 20 of FIG. 1 to accommodate
the additional terminals and wiring, in particular the common block
isolation feature described below.
[0078] It will also be understood by those skilled in the art that
the number of pins in diagnostic receptacle 250 and plug 260 can
vary depending on the wiring and components for a given lighting
system.
[0079] The pin-receiving terminals in receptacle 250 can be
assigned "numbers", as can the mating pins in the continuity plug.
It will be apparent from FIGS. 10, 10A and 10B that lefthand and
righthand receptacles 250 and lefthand and righthand continuity
plugs 260 are mirror images of one another for purposes of the
drawing, but in an actual ballast box installation they will have
the same left-right, up/down order and orientation of terminals and
pins so that the diagnostic tester connector may be plugged into
each in identical fashion.
[0080] The following description of the function and structure of
one diagnostic receptacle 250 and associated continuity plug 260
applies equally to the other lighting system sharing common block
230 in the ballast box.
[0081] Referring to FIGS. 10 and 15, the wire connections between
the various components of the lighting system (ballast, capacitors,
lamp, fuse, common block) and the diagnostic receptacle 250 are
schematically illustrated. Terminals 1 and 7 of the diagnostic
receptacle are crimped together, reserved for use with higher
wattage lamps as will be described below. Terminal 2 is connected
to the voltage output of the ballast. Terminal 3 is connected to
the common block 230. Terminal 4 is connected to the ballast
capacitor terminal. Terminal 5 is open. Terminal 6 is connected to
one terminal of the capacitor 220. Terminal 8 is connected to the
fuse 240. Terminal 9 is connected to the other terminal of
capacitor 220. Terminal 10 is connected to the lamp socket.
Terminal 11 is connected to ground. Terminal 12 is connected to a
common terminal at the ballast. Also, lamp 200 is connected to a
common terminal at the ballast via line 201.
[0082] As illustrated, each continuity plug is provided with
"jumper" wires or other electrical connections between respective
pairs of pins in the multi-pin array. As best shown in FIG. 15,
there is a jumper between pins 8 and 2; between pins 6 and 4;
between pins 9 and 7; between pins 10 and 1 and; between pins 12
and 3. These jumpers in the illustrated embodiment comprise short
loops of wire crimped or otherwise electrically secured to two of
the pins. Pins 11 and 5 are open for purposes described below.
[0083] It will be understood from the foregoing that continuity
plug 260 connects the various components and wiring of the lighting
system when the continuity plug is inserted in diagnostic
receptacle 250. For example, the jumper between pins 4 and 6 in
continuity plug 260 electrically interconnects terminals 4 and 6 of
diagnostic receptacle 250, thereby connecting one terminal of
capacitor 220 to the ballast.
[0084] The above-illustrated and described wiring and jumper
arrangement for the diagnostic receptacles 250 and their continuity
plugs 260 provides an automatic isolation of each ballast 210 and
its associated lighting system components from the common block 230
upon removal of continuity plug 260 from receptacle 250, by
breaking the electrical connection between terminals 3 and 12.
Combined with the wiring of the diagnostic tester connector 20' and
the circuitry of the diagnostic tester 10' (best shown in FIGS. 14A
and 14B), the ballast and associated lighting system being tested
is isolated from common block 230 and the other lighting system in
the ballast box. This feature is important because it prevents
feedback or false readings from the ballast/lighting system not
being tested.
[0085] In operation, each lighting system sharing common block 230
in FIG. 10 is tested in the same manner as depicted above with
reference to FIGS. 1-9, in particular FIG. 5. The main power is
first turned off to common block 230, such that both lighting
systems sharing common block 230 are without power. Before the
tester is connected to the receptacle, the tester itself is tested
for operability of all of the LED's. Next, one of the continuity
plugs 260 is removed from its receptacle 250, automatically
isolating that receptacle and lighting system from common block
230. The diagnostic tester 10' is then connected to the open
diagnostic receptacle 250, causing all of the diagnostic tests of
which the tester is capable to be performed automatically as
described above. Isolation of the lighting system being tested from
common block 230 and the untested lighting system sharing the
common block is maintained throughout the diagnostic testing.
[0086] Depending on the lighting system components which do not
pass the diagnostic tests, one or more LED's on the diagnostic
tester will indicate a faulty component or faulty wiring by an "on"
or "off" or blinking/flashing state as described above. If
components or wiring are found to be defective, they are replaced
or repaired. It will be understood that the procedure followed to
determine which components of the lighting system being tested are
malfunctioning is the same as that described in FIG. 6 above. The
diagnostic tester is then removed from receptacle 250, and
continuity plug 260 is reinserted into the diagnostic
receptacle.
[0087] At this point the testing procedure differs from that
described above with reference to FIGS. 1-9. Rather than turning on
main power to the fixture, the other continuity plug 260 is removed
from the other diagnostic receptacle 250 associated with the common
block, and the previously untested lighting system associated
therewith is tested in identical fashion.
[0088] After the second continuity plug 260 is returned to its
diagnostic receptacle 250, main power to the lighting systems is
turned back on.
[0089] Referring now to FIGS. 11, 11A and 11B, a slightly different
pair of lighting systems and diagnostic receptacles is illustrated
for a higher wattage (e.g., 2000 watt) lamp example. In the systems
of FIG. 11, the lamp schematically illustrated is a "double-ended"
commercially available lamp known to those skilled in the art, with
wiring at both ends to accommodate an extra capacitor and lamp
output from the ballast. In the lower wattage (e.g. 1500 watt)
system of FIG. 10, the extra wires from terminals 1 and 7 are
simply crimped together to form a closed loop; when the receptacle
is used for a 2000 watt lamp, the crimped wires from 1 and 7 can be
uncrimped and connected to the extra capacitor and lamp wire
ballast terminals as shown in FIG. 11. In the illustrated
embodiment, ballasts 210 in FIG. 11 represent commercially
available ballasts manufactured by Advance, which come prewired
with four-wire (FIG. 10) or six-wire (FIG. 11) ballast connections
depending on the bulb type and wattage.
[0090] The continuity plugs 260 for the 2000 watt array are
identical to the continuity plugs 260 used in the 1500 watt lamp
array of FIG. 10. Only the wiring of the diagnostic receptacles has
been changed, and only with respect to the crimped wires between
terminals 1 and 7 in the receptacle. Otherwise, the operation of
the diagnostic tester and the method for determining whether any of
the components or wiring is faulty is identical to that described
with reference to FIGS. 5 and 6 and FIG. 10 above. The only
difference is the fact that there is an extra capacitor and lamp
wire whose function needs to be checked, and this is achieved by
simply uncrimping the wires from diagnostic receptacles 1 and 7 and
tapping them into the ballast at the appropriate terminals.
[0091] It will also be understood in FIG. 11, that isolation of the
common block upon removal of the continuity plugs is identical to
the system illustrated in FIG. 10.
[0092] Referring now to FIGS. 12-14, an actual dual-system ballast
box according to the invention is illustrated generally at 12' and
is shown mounted on a light pole 13 within ladder height from the
ground (e.g., ten feet). FIGS. 12 and 14 also show a modified
diagnostic tester 10'. Diagnostic tester 10' is a modified tester
10' similar to the tester in FIG. 1 contained in a convenient
carrying case 11, preferably formed from a suitable plastic, with a
compartment for cable 18 and a modified diagnostic connector
20'.
[0093] In the modified diagnostic tester 10' of FIG. 14, LED
indicator lights 24', 26', 28', 29', 30', fuse terminals 81', 83',
and push-to-test button 16' generally correspond to like reference
numerals in FIG. 1. As in FIG. 1, the test results will cause the
same pattern of lighting effects on the face of tester 10', with
the exception that the "ballast primary" and "ballast secondary"
LED indicator lights 30, 32 in the tester of FIG. 1 have been
combined into one LED indicator light 30' in tester 10' of FIG.
14.
[0094] Referring to FIGS. 14A and 14B, the circuitry and pin
connections of diagnostic tester 10' and connector 20' are
illustrated schematically to show the differences relative to the
circuitry and pin connections in diagnostic tester 10 of FIG.
4.
[0095] Accordingly, with the invention as shown in FIGS. 10-16, the
ballasts and diagnostic receptacles for multiple lighting systems
can be combined in a single box, with a common block power and
fusing arrangement, and with the main power off can be individually
tested with a diagnostic tester such as 10' with assurance that the
lighting system being tested is isolated from the common block and
any possible backfeed from the other lighting system in that
box.
[0096] It will be understood by those skilled in the art that while
particular receptacle and continuity plug wiring arrangements for
particular lighting systems have been illustrated in FIGS. 10 and
11 for purposes of explanation, and a particular diagnostic tester
10' has been illustrated for the particular receptacle and
continuity plug arrangements of FIGS. 10 and 11, those skilled in
the art will be able to apply the multi-system, single ballast box,
multiple diagnostic receptacle, common block isolation invention to
different lighting systems with different wiring and components.
These and other modifications will be apparent to those skilled in
the art now that we have disclosed the specific embodiments of our
invention.
* * * * *