Can woes

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George Stolz

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Hospital Master Electrician
Has anyone else had issues with cans left on for a prolonged period melting the thermocouple, shorting itself to the can casing?

We use Capri Quicklights (QL1, I think) with a regular white baffle, and use a 65W R30 bulb, where the max is rated at a 75W R30.

I think someone turned it on, forgot about it, and the can just sat there and festered. The label inside the can melted down to a memory pattern, the insulator around the thermocouple melted through, and the can trim has a hat shape when removed from the ceiling, now. :(

My thought is, cans aren't supposed to be on for days at a time, and this occurred in a spec that's been sitting there for months. On one hand, being left on for days unattended is kind of abnormal abuse.

On the other hand, that thermocouple is supposed to prevent this meltdown from happening in the first place. It's an IC-rated can entering the attic space, insulated with that blown paper crud. It's IC-rated, with a bulb 10 watts below it's max.

What's everybody else's take on this? Defective can or abnormal abuse? As far as the GC is concerned, I told him that the cans aren't rated for continuous duty, and to turn the damn things off when the house gets locked. He asked, "What kind of cheap crap are you installing?" I had to partly agree, at least to myself.

I have to say, I am impressed with the arc fault in this case. Might have prevented a catastrophe. :(

[ April 01, 2005, 07:04 PM: Message edited by: georgestolz ]
 
Re: Can woes

My thought is, cans aren't supposed to be on for days at a time...

Says who? Many times they are especially in commercial. I have never seen anything that would restrict a particular fixture to residential only with a "duty cycle".

Apparently that fixture is a piece of garbage. Lamp wattage 10 watts below max, thermal cutout melts down then most of the fixture follows? I would go after the manufacturer, that fixture certainly doesn't meet it's listing requirements.

Just out of curiosity were they purchased from Home Depot or similar?

This is why I stick with Lightolier and Halo. More money but you get what you pay for.

-Hal
 
Re: Can woes

George,

You caught a break on this one,head to Las Vagas before it goes!!!
Anyway the light should be able to stay on until the bulb gives out,agree?
Could it be unique circumstances? maybe just enough of a draft near safety to not open
How about the insulation itself,possible that somehow it got fluffed up with inferior non-rated substance? It's been done before!!
Why not take a fixture out to the shop and do some R&D of your own on it,a lot of houses are at stake here, right
That's my 2 cents worth,lol

frank
 
Re: Can woes

Couple things George,

1st, Make sure the insulators didn't bury the cans if it's blown-in insulation. It will cause problems everytime, usually "Blinking" on and off if the thermal overload is working properly.

2nd, did you "Adjust" the height of the bulb (Up) PAST the point where it is allowed to be? I've noticed they all have a little "stopper" thing that sticks out to prevent raising the bulb past that point. Check the Manufact's directions if you did to see if that's allowed.

3rd, Different brands of bulbs might reflect more heat "down" then others do. If it's happened more then once consider changing bulb brands.

I'de say it was also a defective thermal too. Unless it was covered with paint or other crap that gets sprayed on the ceilings. I started leaving the cardboard circle inside the cans on rough-ins to keep them safe from that stuff.

How many did this happen to?

Dave
 
Re: Can woes

Thanks for the confirmation. (See, when I take both sides, I can take credit for being right either way! :D )

I think I'll bring this up with the boss. ;)
 
Re: Can woes

While i agree that the can should be able to handle 24 7 there is the factor that they might be turning the AC up on days they are not showing it.How much insulation was on it ? And yes the IC thermal should have taken care of this.Call the mfg
 
Re: Can woes

1st, Make sure the insulators didn't bury the cans if it's blown-in insulation. It will cause problems every time, usually "Blinking" on and off if the thermal overload is working properly.
Why? It is an IC rated can.
I would definitely call the manufacturer on this. With a problem of this magnitude they should surely respond.
 
Re: Can woes

Cheap Junk! Cheap Junk! Why does the CUSStomer keep insisting on cheap junk!

What burns me up even more is that sometimes cheap junk is the only thing available, especially in the case of electronic ballasts and even more so ballasts for compact fluorescent bulbs. I am repairing a bunch of outdoor compact fluorescent fixtures that I installed 2.5 years ago. I have a about a 50% failure rate for the lampholders and greater than 50% failure rate for the ballasts. The bulbs did last their rated life, some actually a little more than that.

Knowing what kind of expensive problems that I am having, all outdoor compact fluorescent fixtures from now on will be "incandescent" fixtures with compact fluorescent refit bulbs. With these, I get a new ballast with the bulb.
 
Re: Can woes

A can light that is left on should be able to be left on 24/7 and if a problem arrises the thermal limit should open or the breaker should trip ;)
 
Re: Can woes

"Why? It is an IC rated can."

I didn't say it was a violation, but I've seen it cause problems more than once. With IC cans,
Insulation touching the sides is no problem, but insulation on top simply doesn't allow the heat to escape fast enough.
I've recently started telling the GCs to make sure the insulators don't bury the cans for this exact reason. If I get a call-back for a "blinking" recessed light that's due to a pile of insulation on top of it, they will be charged a service fee per-light! Not to mention the piles of insulation on the floor after I "drop" the can (from below) to fix the problem! Now, when I tell them about what happened to George (Defective Thermal Sensor) I'm sure they will REALLY pay attention.

Dave
 
Re: Can woes

Dave, if you are having problems like that you should contact the manufacturer. An IC can is rated to be completely covered in insulation. With a proper trim and lamp there should be no overheating. I have never ever had this problem.
 
Re: Can woes

I agree with E-Scott, Dave. If the can is sold with an IC rating, then the fixture, trim & lamp (up to and including the labled max. watt) should run 24/7 flawlessly even when under insulation of R gazillion.

George, this Capri fixture obviously has a problem, IMO. Of all the recessed fixtures I've come across in my career, I've never seen a thermal protector damaged like you describe, except by external fire. (Maybe I've been lucky)
 
Re: Can woes

This is not a new problem with cans.20 years ago we did not know about insulation over cans or IC.I suspect many started fires.Even back then i warned the GC to make sure insulation was moved away from them.We all have had the service calls for blinking lights.Easy fast money.What happened here sounds like a defective thermal.You should call the mfg and alert the ahj.Is a possable bad batch out there that might need to be recalled.Would hate to find out that because of a defect some homes burned.I seen a case like this about 2 years ago.Homeowner found about 12 cans without frame or junction box and installed them with 12 penny nails to mount them ,then open wired connected them.On the demo we found the answer,an insulation company was nice enough to put there sticker at the scuttle hole.They had added insulation about 6 months prior to the fire.When i do remodeling if i see the older non IC cans i point out the danger and some will gladly pay to replace them with ic cans.
 
Re: Can woes

Only one can has been affected in this situation. I have had others issues in the past with other trims, but that would take awhile to explain. The key is, this is the standard setup of 95% of the cans I install.

Originally posted by davedottcom:
2nd, did you "Adjust" the height of the bulb (Up) PAST the point where it is allowed to be? I've noticed they all have a little "stopper" thing that sticks out to prevent raising the bulb past that point. Check the Manufact's directions if you did to see if that's allowed.
This picture might illustrate what I'm dealing with a little better:
Canplate.jpg

There are a couple of stops, but I don't think they are intentional stops to the installer.

The first on is the small hole on the bottom of the vertical plate. There is a small tab that sticks out, so that I have to loosen the wing nut quite a bit in order to jump that tab, and get the plate to rise above it's shipped setting.

I also have to slide it straight up, as there are small protrusions from the can housing that prevent it from going higher unless the plate is straight when going past them.

You have an interesting point, Dave, because it's how I was trained to trim out these cans, and if the factory didn't intend for that to be, we've got a problem. The reason we slide it up to it's max altitude is that it looks wrong if we don't, the bulb sticks down below the trim.

It may sound like the two "stops" are there for a reason (as in "How could you be so stupid, George?"), but I always thought they were to retain all the parts during shipping. They are simple to rise above, and the long slot in the plate obviously allows for a much higher max height of the bulb inside the can.

But I will look into this, as a possible cause of the problem. Thanks for all the replies. Once I get the part numbers on Monday, I'll give the manufacturer an e-mail.
 
Re: Can woes

I didn't mention it in my last post, I agree that the thermal sensor is the biggest problem here. :)

Edit to add: I'm not convinced that Capri cans as a whole are junk yet. This is the first problem I've had with them, but I know my buddy at work has had issues with these cans and other trims, which I will discuss further with him and include in my e-mail.

[ April 02, 2005, 10:06 AM: Message edited by: georgestolz ]
 
Re: Can woes

Am sure if they just read this tread they would want involved asap.Maybe a copy should be e mailed to them right now.Willing to bet they would spend what ever to find out what went wrong.Would it not make you think twice before you buy Capri anything ?
 
Re: Can woes

Luckily, I'm not HAVING this problem, I'm AVOIDING this problem!!! :)
Notice I said "IF I get a call..."!!! It was a hypathetical-situation-precaution!!! I've been telling the GCs to stop burying them as a precaution. (Now that I work for myself and I'm liable for EVERYTHING!)
It happened to me once since I started my own buisness. It was a shower trim with a 60 watt bulb in it.(Yes it was rated for a 60 watt type A bulb!) It had about 20" of the stuff ontop of it.

I've seen it a hundred times though when I worked for a contractor back in the 80's. Everytime, removing the insulation fixed the problem.

I didn't know Today's ICs were allowed to be COMPLETELY covered! I thought just the sides were allowed to be in contact. The brand I use just says:

NOTE: IC Fixture may come in contact with insulation.

Does that justify burying it?

:confused:

I'm NOT arguing, just looking for some verification on that.

Dave
 
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