MH Controls Corner: Programming Readiness

July 17, 2019

To meet current energy code and facility requirements, most projects today will include a lighting control system that will require some level of programming to function correctly. The process for how to program systems is different for each system, and each manufacturer. Factory-authorized technicians have the training and experience necessary to program these systems to operate correctly. These services are included on all of our controls projects in order to ensure successful system operation.

For the contractor, having to schedule another vendor to work on one of the many portions of a project can be frustrating. To make things worse, startup services occur at the end of the project, during the final push, to get the project to completion. This is often a chaotic period for the project when all of the loose ends and final problems are being resolved. Schedules by this point are tight, and there is no margin for repeat work.

In order to minimize last minute problems and save time at the end of the project, it is crucial that the system be ready for startup. Frequently, the factory technician is scheduled to the site based on the need for the lighting control work to be completed, but before the installation is ready for the services. When this occurs, all parties end up frustrated with a system that takes more effort to get operational than anticipated, with repeat programming trips, and scheduling headaches.

Successful projects are those where the stakeholders are working together as a team with the common goal of turning over a functional system, on schedule. Following are some tips to help ensure that lighting control system startups happen quickly and easily:

Wiring

To successfully program a system, all fixtures need to be installed, powered up, and tested. All controls components need to be installed, and wired per the factory-provided shop drawings. The electrical engineering drawings are diagrammatic in nature, and do not show all the wiring details necessary for a complete system installation.
Functionally test all wiring to the fixtures prior to the arrival of the technician. All control systems have a manual way to control the lights before the system programming. Verify that the controls are switching fixtures together as intended, and that no switched loads (exit signs and night-lights) are not controlled. Test all UL924 shunt devices at this time, as well, by pressing the test button on the device.
Test the 0–10V dimming wiring by verifying operation with the wires disconnected from the control device. Verify operation by shorting the 0–10V wires together, and observing the lights dimming fully. Removing the short between the purple and the gray wires will bring the lights to full bright. If the fixtures operate correctly with this test, and the lights then dim when plugged into the controller, check for polarity on the 0–10V wires, and/or look for grounding of one of the 0–10V conductors.
If the lighting control system uses Cat 5 (network) cables, it is strongly recommended to use factory-provided, pre-terminated cables. This avoids termination issues that can cause hard-to-troubleshoot system problems that can damage components. On projects where cables have to be terminated on-site (all cables required to be in conduit for example), every cable needs to be tested with a network tester prior to being plugged in to the lighting control system.

Occupancy Sensors

Placement of occupancy sensors is critical for proper operation. Incorrect sensor placement will cause the lights to either remain on when they should not, or not stay on when occupants are present.
Sensors with passive infrared technology require a line of site to the motion to function. Obstructions will cause the sensors to turn lights off when not intended.
Sensors with ultrasonic technology can “see” around corners, making line of sight less important. A high volume of air movement will trigger these sensors, so they need to be at least 6’ away from air diffusers, or the lights may stay on continuously.

Daylight Sensors

Correct placement of daylight sensors is required for correct system operation. Daylight sensors require location-specific calibration, so they must be in the correct location prior to system programming.
Closed loop daylight sensors are those that need to “see” both sunlight and light from electric sources. These sensors point down toward the work plane where the light level is set. The sensor needs to be in the area where the lights are controlled, and cannot be above a fixture that will shine light directly into the sensor.
Open loop daylight sensors are those that “see” only natural sunlight. Install these sensors where they are looking out a window. Installation of the sensor in a location where a wall is “seen,” instead of a window, will cause improper operation. These sensors will not function correctly if a light fixture is shining directly on the sensor.

Completing these tests, and following these guidelines, will ensure that the project is ready for field startup, making it so the technician can get to work, and get the system up and running. When these items are not complete, the technician may have to come back when there is no time in the schedule to allow this to occur.

The MH Companies and [ProSite Services](/prosite-services/about-prosite-services) are dedicated to working as a partner on every project. Please call us with any questions that arise during the installation of the controls system. We would rather take multiple calls per day during installation than have the project schedule jeopardized with costly rework.

If any assistance is needed on this topic, or any other lighting controls related topic, don’t hesitate to contact the lighting controls team at The MH Companies! And remember, whenever you have a technical controls question on any project or application, simply email controls@mhlighting.com. This email address is monitored by our entire controls team. During our normal business hours, we are committed to a four-hour response time for all emails sent to this email address!

This article was written by Clint Conley, our Lighting Controls Department Manager. Clint can be reached at 720.904.8554 or clint@mhlighting.com.