Download Operating Instructions

Freesun（Beijing）Technology Co.,Ltd .
Operating Instructions
Electronic Ballast
575/1200 EB Universal
- flicker free -
Freesun（Beijing）Technology Co.,Ltd.
3FLOOR BAOFENG BUILDING, 160 EAST EIGHT HOUSE, JIANGTAi VILLAGE,
CHAOYANG DISTRICT, BEIJING, CHINA
HTTP://www.bjfreesun.com
TEL: 0086-10-52038831/32
FAX: 0086-10-52038807
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Contents
Page
1. General Remarks ...................................................................................... ............. 3
2
Important Safety Instructions................................................................................. 3
3 .Product Description............................................................................................... 4
4. Start-Up Procedure. ............................................................................................... 5
4.1 Energizing System ............................................................................................ 5
4.2 Control of Light Intensity.................................................................................. 5
4.3 Reduction of Lamp Noise ..................................................................................5
5. Technical Data............................................................................................................ 5
6. Trouble Shooting Guide............................................................................................. 6
7. Connector Wiring……………………………………………………………………8
8. Operating Parts ……………………………………………………………………9
Operating Parts on Front Panel …………………………………………………….9
Block Diagram EB 575/1200 Universal……………………………………………10
Diagram Bottom Plate, back EB 575/1200 Universal……………………………….11
Diagram Heat Sink right EB 575/1200 Universal…………………………………….12
Diagram Heat Sink left EB 575/1200 Universal (1)…………………………………13
Diagram Heat Sink left EB 575/1200 Universal (2)…………………………………14
Diagram Bottom Plate, front EB 575/1200 Universal………………………………..15
Diagram Bottom Plate, bottom EB 575/1200 Universal……………………………….16
Diagram Cover EB 575/1200 Universal…………………………………………………17
9. Measuring Instructions………………………………………………………………..19
Measuring Instructions M 1,2 - 1................................................................................19
Measuring Instructions M 1,2 - 2................................................................................19
Measuring Instructions M 1,2 - 3................................................................................21
Measuring Instructions M 1,2 - 4................................................................................22
Measuring Instructions M 1,2 - 5................................................................................26
Measuring Instructions M 1,2 - 6................................................................................27
Measuring Instructions M 1,2 - 7................................................................................29
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OPERATING INSTRUCTIONS
Electronic Ballast 575/1200EB Universal
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1. General Remarks
Please read the following operating instructions very carefully
before using the Electronic Ballast (EB) the first time. They
contain important information and instructions for the safety, use
and maintenance of the appliance. For your own safety please
follow all safety instructions and warnings. Keep the operating
instructions carefully in a safe place and pass them to any future
owner.
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2. Important Safety
2.1 Warning - High voltages inside ballast ! Danger to life !
Instructions Disconnect EB from power supply before opening
(pull out the line plug). Do not pull on the connection cable, but
on the plug, to disconnect the EB from mains. Any repairs or
changing of the line plug must only be carried out by qualified
personnel or ervice departments.
2.2 Before connecting the Electronic Ballast to the power supply
ensure that the socket is correctly wired. Do not use without
adequate earth connection unless either an isolation transformer
or an earth-leakage trip is employed.
2.3 Lamphead must be disconnected from Electronic Ballast or
Electronic Ballast must be disconnected from mains before
fitting or replacing a lamp.
2.4 The Electronic Ballast must be switched off before
connecting or disconnecting either head or supply cable. Do not
use connectors with permitted cross section of the leads. injury to
the user as well as damage to the ballast could be caused.
2.5 The Electronic Ballast satisfies the standards of the
recognized state of the engineering and the pertinent safety
regulation of DIN EN 60598/1 and DIN EN 60065 for electrical
appliances.
2.6 Supply voltage must not exceed the ranges that are given in
the "Technical Data" (see page5). Check that the power supply
voltage and wiring is suitable for the ballast to be used. Supply
voltages which are greater or less than that specified for the
ballast can cause injury to the user as well as damage to the
ballast. The electronic of the EB is built in a housing with
protective class I and protective rate IP 22.
Ambient operating temperatures must be between -20°C and +
50°C!
Neither back and side heat sinks nor air slots for ventilation
should ever be covered or masked.
The EB must be placed only on solid, flat and dry ground.
Temperature of the ground should be less than 50°C. If the EB
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could slip over the ground, it must be fastened.
Protect EB against direct sunshine. Protection against rain is
needed when wind pushes water drops direct into the air slots of
the EB (acc. to protective rate IP 22).
It is not allowed to operate the EB in high humidity (dew) or in
agressive or explosive gas-air mixtures.
2.7 The Electronic Ballast must be used only according to the
directions in this "Operating Instruction". The manufacturer shall
not be liable for any damages caused by unintended use or wrong
operation.
2.8 The user of the Electronic Ballast is urgently requested to
observe either the following instructions:
lace the ballast into operation if damages are apparent.
information given in these operating instructions, connect and
operate it as shown on the serial number plate.
e the EB from mains (pull out
the line plug).
the EB must be carried out by a qualified personnel or service
only.
Use only original accessories.
worn-out Electronic Ballasts inoperable immediately by
pulling out the line plug and cutting the line cable at the ballast.
Then dispose of the Electronic Ballast properly.
Make sure that children do not operate the EB.
out line plug before you
clean it or do maintenance work on it.
Clean EB dry only or with a moist cloth. Never immerse it into
water.
Do not use the connection cables of the EB for carrying, do not
pull them over sharp edges, clamp them under doors or clamp
them in any other way.
Switch off EB when it is not needed.
3. Product Description The 575/1200 EB is part of an optimized lighting system along with
all 575W and1200W luminaires .
It is suitable for both professional indoor and outdoor use (IP22
protection).
Note: The Electronic Ballast 575/1200 EB meets the European
Council Directive 89/336/EEC of electromagnetic compatibility.
Over an extensive range limits of radio disturbance
characteristic B are fulfilled. But on principle it has to be
classified under characteristic A, group 1.
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Although limits of radio disturbance characteristic A are
prescribed for industrial areas administrative authority can allow
the use of equipment with chacteristic A in other than industrial
areas. Compared to magnetic ballasts there are a number of
advantages when operating daylight-lamps with Electronic
Ballasts:
lamp power
on the power of the lamp (see also "Technical Data" for limits,
on page 5).
on the power of the lamp
ballasts
-in to a casing with type of protection IP22.
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———————
4. Start-up procedure
All operating controls and cable connections are arranged on
the front panel.
4.1 Energizing System
-position.
properly checked daylight luminaire with head
to ballast cable to electronic ballast
Voltage is applied and the Main Circuit Breaker is in "ON"
position.
front plate illuminates. If not, disconnect EB from mains (pull
out line plug) and check power supply and socket (Ref. 2.2. on
page 3)
-position as well on the EB as
on the head. Lamp will ignite after about 5 sec.
ignition was successful.
4.2 Control of light intensity
After warming up, the light intensity of the metal halide
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daylight-lamp may be controlled by the dimming potentiometer
(stepless). The nominal lamp power can be adjusted between
50 - 100% (left stop = MIN, right stop = MAX of power).
4.3 Reduction of lamp noise
When metal halide day light lamps are operated in the flicker
free mode some noise might occur, due to the special
square-wave operation of the lamp.
1. In the position flicker free (yellow LED indicating light) the
electronic ballast will operate flicker free up to 10,000 fps, the
lamp gives out a constant light.
2. In the position "50 Hz" and "60 Hz" (red LED indicating
light) noise will be substantially reduced, the amount
depending on the lamp, in some cases even to almost zero.
The light, however, is NOT flicker free any more. When
operating in this mode, the same limitations for speed of
camera and/or shutter angle apply as for magnetic ballasts. All
other advantages of the electronic
ballast will apply as before!
If in doubt (i.e. remote from ballast) with the flicker analyzer
P.R.O.F. light can be checked to be flicker free or not.
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5. Technical Data
Mains supply
Line Power
: 2290 VA (max.)
Supply Voltage
: 90 - 125V~ / 180 - 250V~ 50/60 Hz
Nominal Current
: 25 - 18A / 13 - 9A
Power Factor
: cos
Lamp connection
Lamp Power
: 575 / 1200W constant control
Power Regulation
: autom. recognition of lamp-types
575W and 1200W
Current Characteristic
: square wave, ca. 75 Hz
Dimming
: Range 50 - 100% of nominal Lamp
power
Starting
: cold start and hot restrike
typical light ripple
: typ. < 3%
Dimensions
width · height · depth
: 200 · 150 · 300 mm
Weight
: ca. 7 kg
Protective Rate
: IP 22
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6. Trouble Shooting 6.1 Does supply voltage correspond with ballast required voltage?
Dual voltage Guide ballasts are autoswitching.
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6.2. Ensure ballast wattage matches lamp power!
6.3 Ensure correct lamp is fitted!
6.4 Connect ballast to power supply and test earth (LED “PE”
has to be on)..
6.5 Re-energizing system: Ensure ON/OFF Switch is in "OFF"
position. Set ON/OFF switch to "ON". Switch should now
illuminate. – WAITAfter approx. 5 seconds lamp should ignite.
6.6 If lamp does not strike, the safety circuit may be broken check if lens door is fully shut and the lens safety switch is
activated.
6.7 Is there a good power supply to the ballast?
6.8 Is the ballast main circuit breaker in ON position?
6.9 If a ballast / head to ballast cable / luminaire does not work
then all three units should be considered faulty. Do not try a
suspected luminaire with another ballast - you may end up with
two faulty
ballasts!
To check if a ballast is good, run it with a known good luminaire
and known good
head to ballast cable.
6.10 If a ballast cuts out after running a few minutes there are a
number of possible failures:
-out in the ballast may have activated due to
extreme ambient temperature or exposure to direct sunlight in hot
summer conditions.
case the ballast
can be used after it had cooled down and the condition causing
the overheating is removed.
drop-outs the ballast switches off to protect itself. If running on a
generator the output should be regulated between 95 – 120 V
respectively 195 - 245V.
-out
switch the ballast "OFF" and "ON" again. The ballast should
start up as normal.
cables will also
cause the protection circuit to be activated. Test the ballast with a
known good luminaire. If cables are suspect, they should be
exchanged with known good cables.
If a ballast is found to be faulty ideally it should be returned
together with the luminaire and head to ballast cable to the
service location for examination.
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Measuring Instructions M1,2 - 1
Check of Power Supply
The admissable power supply (voltage) range for Electronic Ballasts (EB) 575/ 1200 EB
Universal is
90 Veff to 125 Veff and 190 Veff to 250 Veff .
These limits are not to be exceeded either before or during operation of the EB, since
this could
cause operating failure and damages of the EB.
Moreover, operation at voltage limits 90 V / 180 V and 125 V / 250 V is only allowed for
short
periods of time (max. 0,5 hrs).
Power supply can be checked with common RMS- Voltmeters.
At loss of serveral half-cycles in power supply, EB switches to stand-by, and has to be
restarted
(switch OFF, and ON again).
The EB may only be operated if above mentioned limit values are safely kept, and
eventual
failure/malfunction of power supply has been eliminated.
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Measuring Instructions M 1, 2 - 2
Pre-Checks
Even before opening up the EB for an inspection, certain statements in regard to the
operating
conditions of the ballast can be made. To conduct the tests listed in the following, the unit
has to be
operated under no-load-condition.
1st Test - Starting procedure : (Starting sequence of EB-internal contactors/relais,
fuse-test).
2nd Test - Outlet voltages : (Measuring of voltages at the EB's lamp connector).
Depending on the results of both checks the possible point and cause of failure already
might be
located roughly.
WARNING : Electronic Ballasts do not operate separated from mains. Measuring
instruments
therefore always must be connected ground-free. There might be line voltage at the
contacts of the EB's lamp-connector outlet.
The necessary safety rules for this type of operation always have to be followed.
Danger to Life.
1st Test - Start-Up Procedure
To check the starting sequence, the unit will be operated under no-load condition. To do
this,
contacts A and B at the EB's lamp connector have to be bridged to simulate the light
head's safety
loop.
Connect EB to 230 V (mains) power supply. The following sequence of events should
occur if the
EB operates properly:
- About 0,5 sec after switching ON you should hear the clicking of the contactor K7.
- After approx. 3 sec. main contactors K5 and K6 are closed (clicking noise), K7 is
opened
(silent).
- After 1 more sec. ignition contactor K9 will be energized for abt. 0,7 sec
(click/click-noise).
This sketched sequence refers to an EB operating properly.
If there is no reaction after switching ON, the following checks have to be conducted :
- Disconnection of EB from power supply und opening up.
- Checking fuses (2 x T6,3 A) on the Mains Board ( see page 14 )
- If one or both fuses are blown, Mains Board has to exchanged.
- If the fuses are well, the test "M1,2-6: Check of the Mains Board" has to be
conducted.
2nd Test - Outlet Voltages
Contacts A and B remain bridged, since for this test EB also has to be operated under
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no-load
condition.
A) Measuring of Lamp Voltage
Switch ON the ballast. After start-up sequence has passed, a square-wave voltage of
approx. 310
Veff should be measured between contacts C and D of EB's lamp connector. Use f.i.
digital multimeter
with adequate voltage range or oscilloscope.
WARNING: Mains powered measuring instruments have to be connected ground-free
to the EB.
Otherwise high currents might flow across the ground/earth contact which might
damage EB and/or measuring instruments.
The respective safety rules have to be watched.
Basically three different measuring results are possible:
1. U = 310 V :This is the normal outlet voltage.
2. U = 150 V :Defective output bridge, missing half-cycle of lamp voltage.
3. U = 0 V : Unit has switched off electronically. Defects/failures possible in all areas.
Result 1. : EB-failure possibly caused by defective lamp cable or lamp head. Replace
lamp head
and/or cable by checked-out system. If after this there is no ignition (no ignition noise in
the lamp), lamp's ignition voltage should be checked.
Result 2.
and 3. : Defect(s) in the area of the power modules. At 150 V lamp voltage (2.) at least
one
power module of the output bridge of the LF-Gate Drive Board has failed. At 0 V the
defect might be in the buck-converter as well as in the output bridge.
Generally with the results 2. and 3. test "M 1, 2-4 : Power Modules" has to be
conducted.
B) Measuring of Ignition Voltage of the Lamp
Ignition of the lamp happens automatically. Ignition contactor K9 switches the lamp
voltage for appr.
0,7 sec. to pin F of the lamp connector. This voltage can be measured with an
oscilloscope (ground
free!!) between pins F and D (= reference point, "Llow").
Digital multi-meters are not particularly apt for this measurement, since lamp voltage
applies only for
abt. 0,7 sec., and most multi-meters need a longer time to indicate a value.
Another method of measuring can be to connect a 230 V incandescent lamp (max 40 W)
between pin F
and D of the lamp connector of the EB. This incandescent lamp then has to be lit for abt.
0,7 sec after
EB has been switched ON.
If there is no ignition voltage, although the output voltage between C and D is correct,
then the ignition resistors (2 x 47/5W) on the LF-Gate Drive Board are defective and
have to be changed.
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A possible cause could be a defective igniter of the lamp. The respective light head
should be seriously
checked by all means, to avoid repetitive damage of this or other EB's.
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Measuring Instructions M 1, 2 - 3
Failure of the Mains Curcuit Breaker
The Mains Curcuit Breaker is tripping, if the EB is operated on Line voltage > 270 Veff
or an
internal short circuit causes an exceeding mains current.
The following measurements should be conducted at the EB for identification of the
failure.
- Disconnect EB from power supply and switch on Mains Circuit Breaker. Connect
Ohmmeter
between the contacts of the EB's Line plug. If there is a short circuit at the power
supply side of the EB,then the varistor on the Mains Board (see page 14) has to be
exchanged.
- This varistor has been installed for a sole purpose: to protect the EB from overvoltage.A
damaged varistor therefore generally indicates, that the EB has been operated with
overvoltage
from the power supply side.
- If there is no short circuit at the mains plug to be detected, the unit has to be opened up,
and
at first a multi-meter(diode testing range)-test has to be conducted between the flat
connector X10 and X12 of the Input Rectifier (see page 16).
- If the multi-meter shows conducting/passage state of the diode in one direction, and
"OL" in the opposite direction, the mains rectifier is defective and has to be changed.
- In any case an additional test "M 1, 2 - 4: Power Modules" should be conducted.
- If there is passage state of the diode in both directions, there is a short circuit at the
DC-side
of the mains rectifier; test "M 1, 2 - 4 : Power Modules" is required.
- If the multi-meter show "OL" in both directions, test "M 1, 2 - 4 : Power Modules"
has to
be the next step.
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Measuring Instructions M 1, 2- 4
Test Power Modules
WARNING: Electronic Ballasts do not operate separated from mains. Measuring
instruments
therefore always must be connected ground-free. There might apply line voltage at
contacts or connections of the EB. The necessary safety rules for this type of
operation alwas have to be followed.
Danger to Life.
For the checks described hereafter, the power supply of the output stage should be
disconnected
from the mains power supply input.
This way it is possible to inspect all control signals and electronic voltages inside of the
EB without
causing further damages to the EB.
In any case, prior to disconnecting the power modules, the DC-voltage at the input
capacitors has to
be checked. The multi-meter has to be connected to testpoints P5.Y1 and P5.Y2 (see 17;
screw
contacts of the Capacitor Board).
If voltage is > 0 V , the input capacitors have to be discharged (f.i. with incandescent
lamp
230V/40W or resistor 1k/ 20W connected to the testpoints P5.Y1 and P5.Y2).
The disconnection from input power supply is achieved the easiest way by pulling off
cables from flat
connectors P4.X8 and P4.X9 on the Mains Board (see page 14).
After this disconnection the input capacitors will not be charged anymore. Power supply
passage is
interrupted.
CAUTION : A protection circuit on the Control Board stops the drive of the HF
converter, if the
input capacitors are discharged.
To conduct the following test, one end of a diode (1N4148) has to be soldered off from
the control
board. This is marked on page 12. From serial No. 0121001895 it is realized with a
jumper.
1. Test of the Power Transistors (Power-FETs IRFP 450 and IGBTs GT50J101)
Always the internal free-wheel diode of the FETs and IGBTs is checked. The multi-meter
is switched
to the Ohm-range, especially tuned in for diode measuring, and connected to drain and
source of
the FETs, respectively collector and emitter of the IGBTs.
All IGBTs of the output bridge (see page 15, LF-Gate Drive Board) have to be checked,
and also
the 3 FETs of the HF-converter (see page 16, HF-Gate Drive Board).
Philips Multimeter PM will f.i. show the following values:
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FET IRFP 450, not damaged: appr. 490in one direction "OL" in the opposite direction.
FET IRFP, 450 damaged: Short circuit (appr. 2...3) or "OL" in both measuring
directions.
For the IGBTs GT50J101 there are similar values.
It goes without saying, that multimeters of other manufacturers are apt for this test. The
correct
Ohm-value then has to be evaluated by measuring a FET or IGBT which works properly.
2. Test of the Free-Wheel Diodes (BYT 30 PI 800)
The free-wheel diode of the HF-Gate Drive Board (BYT 03 PI 800) is tested on the same
way as the
FETs are tested (see page 16).
Philips Multimeter PM will f.i. show the following values:
BYT 30 PI 800, not damaged : appr. 450in one direction, "OL" in the opposite
direction.
BYT 30 PI 800, damaged : Short circuit (appr. 2...3) or "OL" in both measuring
directions.
If defective power-FETs, IGBTs or damaged free-wheel diodes are detected, the
respective
semiconductors have to be changed. In any case the base drive pulses have to be checked.
This is the
only way, to prevent repetitive damage of the power semiconductors, in case f.i. there is a
fault in the
gate drive circuit.
3. Test of HF-Gate Drive Board
To check the drive signals, the EB also has to be operated under no-load condition, with
the power
supply internally disconnected. Bridging of contacts A and B of the lamp connector also
has to
remain.
On the HF-Gate Drive Board there are 3 LED, who indicate the working conditions of the
board.
(see page 16).
- LED1 (red) : Failure on the HF Drive Board, normally not lit.
- LED2 (green) : Operating voltage supply okay, when lit.
- LED3 (yellow) : Drive signals of the IRFP 450 okay, when lit.
If LED2 is not lit, the test "M1, 2- 6 : Check of the Mains Board" has to be performed.
If the Mains Board works well, the HF-Drive Board has to be exchanged.
If LED3 is not lit, the test "M1, 2- 7 : Check of the Control Board" has to be
performed.
If the Control Board is ok, the HF-Drive Board has to be exchanged.
After fixing possible failures or exchange of defective boards the drive signals of the 3
FET IRFP
450 have to be checked with an oscilloscope. Measuring points are gate and source at
each FET
(see page 16). There has to be a square wave (FET on = 13V, FET off = 0V, frequency
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20 kHz,
switch on time abt. 95%) to be measured.
Fig. 4.1 shows that signal.