High failure rate on new LED drivers

[dnvr99.ex]

Hey guys,, we're dealing with a frustrating issue on a commercial fit-out. We installed about fifty integrated 2x4 LED troffers (40W, Brand A) a few months ago, all running on 0-10V dimming. We've had a high rate of failure already.. about 15-20% of the fixtures. The common failure mode is either intermittent flickering at mid-dim or the fixture is completely dead. The dead units show line voltage but zero output from the driver. Swapping the entire fixture fixes it, confirming an internal component failure.

I suspect a systemic issue with the driver's thermal management or low-quality electrolytic capacitors, leading to early failure (under 1000 hours).. Has anyone seen this type of rapid, high-volume failure with integrated LED products?? Is there a reliable field test for a problematic 0-10V driver besides just checking input/output voltage? I'm trying to determine if I need to push for driver replacements or full fixture replacements.

Thanks for your help!!

 

[PrincessJade]

that’s way too high a failure rate. Sounds like a bad driver batch. Those integrated fixtures usually use low-grade caps that cook fast in warm ceilings. If it’s across multiple circuits and not heat-related locally, I’d push for full fixture replacements under warranty instead of wasting time swapping drivers.

 

[h0td0g]

Is there a reliable field test for a problematic 0-10V driver besides just checking input/output voltage?

yeah, of course. You need to isolate the dimming circuit, short the dimming circuit, and also check for thermal stress (using an infrared thermometer or camera)

 

[Alan]

Fifteen to twenty percent failure in a few months definitely points to a bad production batch or driver design issue. If anyone’s dealt with similar cases, did the manufacturer agree to a fixture swap, or just send new drivers? Be good to know how different brands handle warranty claims like this.

 

[PGB1]

If anyone’s dealt with similar cases, did the manufacturer agree to a fixture swap, or just send new drivers? Be good to know how different brands handle warranty claims like this.

In my home, I installed 5 Halo branded Cooper fixtures (model HLBSL-4069FS351EMWR) One driver failed after 8 months.
Cooper not only sent a replacement complete fixture (driver & lamp), but two extra complete fixtures "just in case". I had them in 2 days.
I thought that was premium service. (Two years later, no more failures.)

I bought two Cree PAR 38 outdoor flood lamps. Both failed in just over a month. Warranty is 10 years.
The Cree representative told me they "had some problems" with that batch. Did they send me new ones? Nope. They said that they would send refund, minus sales tax, of what I paid. Replacements cost 9.00 USD more than the first purchase.
I thought that was not so much premium service.

 

[Alan]

In my home, I installed 5 Halo branded Cooper fixtures (model HLBSL-4069FS351EMWR) One driver failed after 8 months.
Cooper not only sent a replacement complete fixture (driver & lamp), but two extra complete fixtures "just in case". I had them in 2 days.
I thought that was premium service. (Two years later, no more failures.)

I bought two Cree PAR 38 outdoor flood lamps. Both failed in just over a month. Warranty is 10 years.
The Cree representative told me they "had some problems" with that batch. Did they send me new ones? Nope. They said that they would send refund, minus sales tax, of what I paid. Replacements cost 9.00 USD more than the first purchase.
I thought that was not so much premium service.

that's some great feedback and experience. glad you can share it with the community!

 

[William Thompson_33]

I’ve run into the same thing with some of these newer drivers. What helped me on a recent project was working with a group called Relumination they handled the design side on a warehouse job I was involved in, and it was the first time I didn’t get hit with random driver failures a few months later.

I don’t know exactly what they did differently, but the fixtures/drivers they specced have been solid so far.

Anyway, curious what brands are giving you the most trouble? I’m still seeing weird failures even straight out of the box sometimes.