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Operating Instructions

Electronic Ballast 575/1200 EB Universal

- flicker free -

FreesunBeijingTechnology 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
2

Page

1. General Remarks ...................................................................................... ............. 3 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 Wiring8 8. Operating Parts 9 Operating Parts on Front Panel .9 Block Diagram EB 575/1200 Universal10 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 Universal17 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

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. 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 -20C and + 50C! 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 50C. If the EB

2. Important Safety

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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. 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. 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 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. 490in 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. 450in 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.