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New Light Switches To Conserve Power (and spend money)

Charles (in GA)

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Way back in time, I installed lights in my "shop". Here is the thread.

http://www.garagejournal.com/forum/showthread.php?t=21048

What I did was install Twelve 400 watt Metal Halide lights. Three rows of four lights each. These draw 4.0 amps at 120v for a total load of 480 watts per fixture, do the math, thats 5,760 total watts. Makes you cringe when you think about that meter "spinning" (its electronic now, so it doesn't actually spin, buttttttt.........)

Here is what it looks like with everything on.

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Well, while I like lots of light, there are times when I simply do not need all of that light. Up till now, I was turning on one or two rows to save power, but often, that left one end darker than I cared for.

The lights are wired on three circuits, each with one row of four on a circuit. These are MULTI-WIRE circuits, two hots fed from a double pole, common trip breaker, thru a double pole light switch, and sharing a common neutral. Thus two lights on the A side (or red wire side) and two lights on the B side (or black wire side), using split outlets, clearly marked A and B on the top and bottom of each receptacle.

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The switches are installed in a five gang panel. They are P&S double pole, 30 amp switches I picked up at Home Depot on clearance for $7 each.

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What I was looking for was a way to turn on just half the lights, or all of them. I started looking and found that Hubble, Cooper, and Leviton all make double pole, double throw, center off, maintained (ie they stay on, and are not momentary) switches. Looked in Grainger and found the Leviton switches, 1286-I , a 20 amp rated switch was just what I needed, but they wanted $121 each for them, and I needed three of them. Finally found three of them from an Ebay seller, Fruitridgetools, for $49.95 each and $5 shipping for all three.

After thinking about it for a while, I installed the switches so that if you push down, you turn on the A side of the circuit only, and if you raise the switch up, you turn on both sides of the circuit (this is accomplished by a couple of pigtails from two of the terminals wire nutted together).

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In the top pic the lights are from right to left, plugged in, A then B then A then B. This allows me to turn on the far right lights, and the next to the left most lights. In the middle row, I reversed which socket the plugs were in, thus the first and third rows are the first and third lights, while the middle row has the second and fourth lights on.

Now I can only burn 2,880 watts if I want to, and still have decent lighting.

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I also can turn on all the lights, plus two 500 watt quartz floods on the back wall, plus the two 8ft T5HO fixtures over the workbenches for a total of 7,192 watts of light. Sheesh! Georgia Power loves me.

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Edited to add a wiring diagram for the switch. I had this posted originally in a Temp thread in the test area for a specific individual, thought I'd add it here.

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Charles
 

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nehog

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Wow, I thought only I was crazy enough to do that!

I wired my metal halide for 240 volts, because of the 'blistering' current requirements. Four fixtures per bay (three bays.) I measured the current on mine and it is the same as yours.

My shop also has T-8 florescent lighting too. Eight fixtures per bay (three bays.) Each bay (eight fixtures) draws just over 400 watts total. So one bay of florescent is equal to one single metal halide fixture.

At the shop entrance, I have three switches for the florescent lights, and three switches for the metal halides. And a switch (timer actually) for a sodium light outdoors. A lot of switches, but it works well. There is no reason (IMHO) to light the entire building when 90% of what I do is at the end where the shop proper is.

And, yea, I bet the power company sees a big spike in current usage when I turn everything on!
 

Aceman

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Since we're on the topic of A/B switching...

The T5HO 6 lamp fixtures we use have 2 ballasts and allow for A/B switching. You can either have 4 lamps on or 6 lamps on, I believe. Just an alternative...

I know most folks don't have the ceiling height for T5's but if folks want to dual switch their lights(i'm talking flourescents), make sure they have dual ballasts or one ballast with two switchable inputs.

I think it's a great way to save power if you really don't need full brightness, shop door is open, etc.
 
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Charles (in GA)

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Since we're on the topic of A/B switching...

The T5HO 6 lamp fixtures we use have 2 ballasts and allow for A/B switching. You can either have 4 lamps on or 6 lamps on, I believe. Just an alternative...

I know most folks don't have the ceiling height for T5's but if folks want to dual switch their lights(i'm talking flourescents), make sure they have dual ballasts or one ballast with two switchable inputs.

I think it's a great way to save power if you really don't need full brightness, shop door is open, etc.

Which is the second reason for changing out the switches. Someday, when I stumble into some 6 or 8 lamp T5HO fixtures I can hang on hooks to replace these MH fixtures, I will wire them with two cords and plugs, one for each ballast, and this will allow me to turn on half a fixture or all of the fixture.

Charles
 

Gary S

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Great idea!

Metal halide puts out lots of light, but you really pay for it. This would be a way to have maximum light available when you need it, and still be able to throttle it back when you don't.

With that level of power consumption, you should be able to heat your shop with just the lights.
 
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Charles (in GA)

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The reality is, a 400w MH puts out about 36,000 lumens, and draws 480w, 4.0 amps, 120v

An 8 bulb T5HO fixture puts out 35,200 lumens, and draws 432 bulb watts, 4.0 amps, 120v

not any real savings, not near what the lighting people would have you believe.

Charles
 
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Charles (in GA)

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Thought I'd add to this thread.

During the summer, I ran my shop Ceiling Fans every day I was home. I never had any trouble remembering to turn the fans off as they were on high speed and made enough noise that would catch my attention.

In the fall, I've run the fans on low or medium low a couple of times when running my Shop Heater, and each time, I've walked out and left the fans running. They are quite on low speed, I don't hear them, I have my back to them, and its dark, and I reach across the electric panel to the far left and flip off the lone switch that controls a pair of quartz 500w floods that I use for general area lighting. I simply don't notice that little fan switch right in front of me.

Well, I pondered the issue for a while, and decided I needed a pilot light to remind me when the fans were on. After looking in catalogs and seeing how expensive they were I decided the pilot light was going to be too expensive and a problem to install. I finally realized that they do make pilot light snap switches. After all, the switch for my quartz floods is internally illuminated when it is OFF to aid in finding it in the dark, so why not get one that is illuminated when it is ON.

Started looking and found the Leviton 1221-PLR which is a 20 amp rated industrial snap switch that has a clear red toggle with a light inside it. Grainger wants $44 for it, way too much, but I found it on Ebay, from the same people I got the light switches from, frwoodworking (Fruit Ridge Tools), new in the box for $3.95!!!! Shipping was about the same amount, so for less than $8 I can now remember to turn the fans off when I leave the shop.

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The grey screw on the top left is the neutral connection needed to make the pilot light work. According to the wiring diagram, the brass screw on the top right is the line, and the black screw on the bottom right is the load. This turned out to be incorrect, as I connected it this way and found the light burned all the time. Reversed the wires, with the line on the black bottom RH screw and the load on the top RH and it worked as it is supposed to, switch off, light off, switch on, light on.

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For eight bucks, I happy and hopefully won't come out to the shop the next day or even a couple of days later and find the fans running.

Charles
 

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sberry

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My shop is large, I do not run all of the lighting all the time. I have a 400 watt sodium over my general gab work area/benches and about a dozen 4 lamp flors all switched up, its very deliberate for me to turn on lights, got a couple 4 ftrs on a swinging boom over projects and about 4-500W quarts on stands with switches. a couple 3 2 lamp 4 ftrs here and there over benches. I got everything plug and cord connected I can and use switched outlets. My office, 2 4 ftrs each on own switched outlet and another part of this scheme is in shop I hang 2 fixtures with 9 watt cfl, I can walk anywhere and use the bathroom without touching a switch, tend the stove in winter. I run another one clipped on a beam in my office. I got them plugged in to a hot outlet.
A small bug zapper makes a great night light in a building. I hookied garbage can lid underneath to collect bugs. My interior is all white low watt cfl really is ideal, can walk anywhere in shop at any time to destination and then if needed turn a light on. Can walk in to office, use computer. get a coffee or go into bathroom/laundry without switching. I could add a window but it all works as simple and easy as I can get.
 
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Teken

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Started looking and found the Leviton 1221-RPL which is a 20 amp rated industrial snap switch that has a clear red toggle with a light inside it. Grainger wants $44 for it, way too much, but I found it on Ebay, from the same people I got the light switches from, frwoodworking (Fruit Ridge Tools), new in the box for $3.95!!!! Shipping was about the same amount, so for less than $8 I can now remember to turn the fans off when I leave the shop.
Charles

I have no clue how this company (Grainger) stays in business with the insane prices they charge the average guy. :wtf:

We have a commercial account with them for almost 30 years and to this day maybe 2% of our purchases come from them.

With respect to Fruit Ridge Tools, they are bar none the best E-Bay vendor I have ever dealt with.

Great communications, prices, and fair shipping and handling across the border. They are definitely one of my first vendors I go to IF I need something electrical.

Teken . . .
 
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Charles (in GA)

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With respect to Fruit Ridge Tools, they are bar none the best E-Bay vendor I have ever dealt with.

Great communications, prices, and fair shipping and handling across the border. They are definitely one of my first vendors I go to IF I need something electrical.

Teken . . .

Good to hear that. Thats the experience I've had on two purchases now, so I can expect it to continue with future purchases.

Charles
 
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Rogue1987

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I have no clue how this company (Grainger) stays in business with the insane prices they charge the average guy. :wtf:

We have a commercial account with them for almost 30 years and to this day maybe 2% of our purchases come from them.
They don't give a damn about the average guy. They cater to large commercial and government accounts who really don't care about the price (Either price isn't an object or the cost is re-billable to someone else...hopefully at a mark up. If its a contractual based mark up, the higher the price, the better!)
 

byoungblood

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I have no clue how this company (Grainger) stays in business with the insane prices they charge the average guy. :wtf:

Most of their larger accounts have contracted pricing or are ordering in sufficient quantities to get volume discounts. If they're doing enough business with them, they're not paying full list.
 

Teken

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They don't give a damn about the average guy. They cater to large commercial and government accounts who really don't care about the price (Either price isn't an object or the cost is re-billable to someone else...hopefully at a mark up. If its a contractual based mark up, the higher the price, the better!)

Most of their larger accounts have contracted pricing or are ordering in sufficient quantities to get volume discounts. If they're doing enough business with them, they're not paying full list.

I can't disagree. :spit: I see this first hand in many of the government sites I visit so more than likely both of you are correct.

But, seriously . . . Asking $44.00 for a freaking lit switch?? :headscrat :wtf:
 

gatchel

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I have no clue how this company (Grainger) stays in business with the insane prices they charge the average guy. :wtf:

Teken . . .

Every time I have ever needed something from Grainger, if they didn't have it at that moment it was there in less than 24 hrs, usually by 7:00AM the next day. To me, if you need something, the price is justified. For Joe Homeowner there's Amazon or Ebay.
 

evan_880

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Hey charles,
lights look great. quick off topic question. I have the exact same fan switches as you and i would assume same fans (hampton bay?) does your switch make the fan go in reverse or not?
In my manual it says that that switch is supposed to reverse the fan for cooling or moving the hot air down depending on rotation but when i wired mine as they showed it doesnt work. i just have 4 speeds for the fan.
Anyway thought i would ask. Lights look great.
evan
 
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Charles (in GA)

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Hey charles,
lights look great. quick off topic question. I have the exact same fan switches as you and i would assume same fans (hampton bay?) does your switch make the fan go in reverse or not?
In my manual it says that that switch is supposed to reverse the fan for cooling or moving the hot air down depending on rotation but when i wired mine as they showed it doesnt work. i just have 4 speeds for the fan.
Anyway thought i would ask. Lights look great.
evan

These switches are provided with the Hampton Bay INDUSTRIAL fan, HD number 526-012. The switch does NOT have any reversing feature. The fan can be reversed but you have to have a ladder or lift and access the fan itself, raise the "bell" cover on top of the motor, and you find a slide switch which you can set to the reverse position and then reinstall the "bell" cover and the fan will run in reverse.

I have stated this in several different threads, and sometimes someone will disagree, but I firmly believe that it is a waste to reverse a ceiling fan. In the heat, you want to feel the air movement (and in my case, blow the hot air down to a point where the outside breezes will carry the heat out of the open building) and in the winter, you want to push the heat down to the floor as efficiently as possible. (in a high ceiling shop or a steel building like mine, blowing up is a waste as the air will not make its way to the floor, but rather will circulate in a global circulation around the fan, up, down and back into the fan) In a small, low ceiling room with a flat ceiling, its possible to run the fan blowing up and have it push air across the ceiling and down the walls, but in a large, tall shop, it ain't gonna happen.

Charles
 

evan_880

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Okay great thanks for the reply. I know in my manual it says the switch that came with it was reversible but not so much.

I do agree with you 100% about not reversing in your situation. I only have 11'6" ceiling so for me I feel it would work well to reverse it and not feel the air hit you just move the warm air down.

I didn't know there was a slide switch in the bell. Thanks!
Again great looking shop
 

fionasdad

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Elk Grove, California
I can't disagree. :spit: I see this first hand in many of the government sites I visit so more than likely both of you are correct.

But, seriously . . . Asking $44.00 for a freaking lit switch?? :headscrat :wtf:
My dad was a Sales Rep. for Grainger and retired from them. Great company.

You're right though they aren't really after the small accounts but the larger one's get much better pricing.

If I remember correctly from my dad (he retired back in 1999) they have a sliding scale for regular clients and they pay much less than the catelouge price. Regular clients get assigned to Sales Reps. who make calls on the clients. These clients tend to get really good prices. All depends on the volume sold...
 
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