eta plus ELC X Series Technical Documentation Manual

UV-

TECHNOLOGY

Technical Documentation

ELC

®

X-Series

GB

eta plus electronic gmbh

Lauterstraße 29, D-72622 Nürtingen, Telefon +49 (0) 70 22 - 60 02-80, Fax +49 (0) 70 22 – 6 58 54

Postfach 1411, D-72604 Nürtingen, e-mail: info@eta-uv.de

––––––––––––––––––––––––––––

Eingetragen unter HRB 724321 AG Stuttgart, USt.-Id.-Nr. DE 146267800

Geschäftsführer: Dr. Peter Schwarz-Kiene

ELC X-Series-V1.5-06.18-GB subject to technical alterations

ELC

®

(„Electronic Lamp Control“) is a registered trademark of

IST Metz GmbH.

Contents page I

ELC X-Series-V1.5-06.18-GB subject to technical alterations

Contents

1 Safety ................................................................................................ 1

1.1 Definition of symbols ................................................................................... 1

1.2 Safety advice ................................................................................................ 1

1.3 Correct operation ......................................................................................... 2

1.4 Extended use ................................................................................................ 2

2 Description of functions .................................................................... 3

3 Installation ........................................................................................ 4

3.1 Mounting of casing ....................................................................................... 4

3.1.1 Mounting of single ELC .................................................................................... 4

3.1.2 Mounting in a stack .......................................................................................... 5

3.2 Connection ................................................................................................... 6

3.2.1 Connection overview of ballast types X4 – X8 .................................................. 6

3.2.2 Profile of the cable gasket X4 – X8 ................................................................... 7

3.2.3 Overview power connections X4 – X8 ............................................................... 9

3.2.4 Connection overview of ballast types X12 – X36 .............................................10

3.2.5 Overview profile of the cable gasket X12 – X36 ...............................................10

3.2.6 Overview power connections X12 ....................................................................13

3.2.7 Overview power connections X16 – X36 ..........................................................14

3.2.8 X100: Mains connection ...................................................................................15

3.2.9 X600: Connecting the lamp feeder cable ........................................................16

3.2.10 Overview of control and bus connections ....................................................18

3.2.11 X1 / X2: BUS connections ............................................................................19

3.2.12 X3: BUS T-coupler .......................................................................................20

3.2.13 X805 and X806: Control cables ....................................................................21

3.2.14 X808/X300: Service interface .......................................................................23

3.3 Comments on the safety functions of the ELC ........................................... 25

3.3.1 Safety relay ......................................................................................................25

3.3.2 Initialisation signal ..........................................................................................25

3.4 Configuration ............................................................................................. 26

3.4.1 Setting up the BUS address ............................................................................28

3.4.1.1 PROFIBUS .......................................................................................... 28

3.4.1.2 MODBUS ............................................................................................ 29

3.4.2 Checking the BUS connection and error indication ........................................30

3.4.3 Setting lamp power via BUS ............................................................................31

3.4.4 Extended temperature and power range ........................................................33

3.4.5 To read out ELC serial number and software version ....................................35

Contents page II

ELC X-Series-V1.5-06.18-GB subject to technical alterations

4 Operation of the ELC ....................................................................... 36

4.1 Initial operation .......................................................................................... 36

4.2 Switching on the ELC .................................................................................. 36

4.3 Activating the safety circuits ...................................................................... 36

4.4 Switching on the lamp ................................................................................ 37

4.5 Dimming operation..................................................................................... 39

4.6 Switching off the lamp ............................................................................... 39

5 Monitoring, warning, error, repair ................................................. 40

5.1 Mains voltage monitoring .......................................................................... 40

5.2 Warning messages ..................................................................................... 40

5.3 Error ........................................................................................................... 42

5.3.1 Error messages ...............................................................................................42

5.3.2 Display messages and trouble shooting .........................................................42

5.3.3 Earthfault indication via Special Function Register in MODBUS

control .............................................................................................................45

5.3.4 Resetting the error register ............................................................................46

5.3.5 Exchanging the main board .............................................................................46

5.4 Maintenance ............................................................................................... 49

5.5 Repair ELC .................................................................................................. 49

5.6 Disposal of ELC .......................................................................................... 50

6 Technical Data ................................................................................. 51

6.1 ELC X4 ........................................................................................................ 51

6.2 ELC X6, X6B, X6i ......................................................................................... 55

6.3 ELC X8, X8B, X8 extended range, X8i, X8F ................................................. 59

6.4 ELC X12, X12B, X12i, X12F ......................................................................... 63

6.5 ELC X16, X16B, X16i, X16F ......................................................................... 67

6.6 ELC X24, X24B, X24i, X24F ......................................................................... 71

6.7 ELC X36, X36B, X36F .................................................................................. 74

1 Safety page 1

ELC X-Series-V1.5-06.18-GB subject to technical alterations

1 Safety

1.1 Definition of symbols

Stop (Stop Danger). This symbol warns of serious danger of severe injury to

persons. It must be strictly observed.

Attention (Warning). This symbol indicates information the non-observance of

which can lead to extensive damage to property. The safety warning must be

strictly observed.

Information. This symbol indicates key information on use. Non-observance can

lead to failure.

1.2 Safety advice

The ELC must be installed and connected in compliance with existing regulations

and practices. This is e.g. EN 60204-1 in Europe.

Repairs on the ELC may only be carried out by the manufacturer.

The installation, starting up and maintenance may only be carried out by skilled

electricians.

Do not open the ELC before it is disconnected from the mains. BEWARE OF

RESIDUAL VOLTAGE! The unit may still be live up to several minutes (see label in

the ballast) after it has been switched off.



1 Safety page 2

ELC X-Series-V1.5-06.18-GB subject to technical alterations

The ELC causes a leakage current given in chapter 6.

Safeguarding by means of leakage current protection type A and type AC

according to IEC 60755 is not permitted!

The ELC operates in principle as a frequency converter and is equipped with a

mains filter whose leakage current could trip the earth leakage detector RCD.

Contact to the grounding connector must always be ensured.

Additional measures must be taken to ensure that there is no danger when

touching the appliance. This could be by means of a universal leakage current

protection type B, taking into consideration the increased response threshold, or

by means of an independent equipotential connection.

The leakage current through the interference suppression capacitors demands

as per EN 50178 the use of a second protective earth conductor in parallel to the

first one. The cross-section of each earth conductor corresponds at least to the

cross-section of an outer conductor.

1.3 Correct operation

The ELC is conceived as an electronic ballast exclusively for the operation of

lamps approved for this ELC type.

Any other use is deemed as misuse. The manufacturer will not assume liability

for damage resulting from misuse.

A pre-requisite for authorised operation of the ELC is the observance of both the

operating and maintenance instructions and the safety advice.

1.4 Extended use

Extended use beyond the operating specifications as stated is not permitted.

The manufacturer will not assume liability if the equipment is used in any other

way. The operator acts at his own risk.

Any operation beyond the scope of the authorised operation is considered to be

misuse.

2 Description of functions page 3

ELC X-Series-V1.5-06.18-GB subject to technical alterations

2 Description of functions

The electronic ballast ELC is designed to operate medium pressure discharge lamps as

described in chapter 6.

In contrast to conventional ballasts (inductive lamp ballast or transformer or transformer with

transductor), with an ELC the lamp is operated with high frequency (approx. 100 kHz). The

lamp does not flicker and dimming is infinitely adjustable within a wide power range (see

chapter 6).

Dimming

The possibility of dimming the lamp has two advantages. Firstly the lamp can be switched to

minimum load (standby operation) during longer idle times and energy can thus be saved.

Secondly the optimum lamp power can be determined and adjusted as appropriate.

Power control

The ELC offers a high level of lamp power constancy due to its integrated power control.

Variations in operating voltage of 400-480V  10 % do not affect lamp power. Between 310-

360V a reduction of output power according to chapter 6 has to be taken into account.

Ignition device

When the lamp is switched on the ELC initiates trigger pulses to fire the lamp; a separate

ignition device is not required.

Other performance characteristics

 High level of electrical efficiency.

 Low harmonic distortion of the mains current due to integrated power factor corrector.

 Configuration, control and monitoring of the ELC is carried out via BUS-interface.

 The ELC monitors the insulation resistance of the lamp output wiring (earth fault control).

 The potential of both lamp outputs is insulated from that of the supply voltage.

 The ELC is both short-circuit proof and safe in open circuit operation at the lamp output.

3 Installation page 4

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3 Installation

3.1 Mounting of casing

The ELC may only be installed as described in 3.1.1 and in 3.1.2, allowing for at

least the minimum spacing as shown in Fig. 3.

Horizontal mounting upside down is not allowed. All vertical mounting

orientations are possible.

The ELC should not be mounted in the immediate proximity of sensitive electronic

equipment. An appropriate distance must be maintained to scatter field

transformers or other inductors.

The ELC is equipped with built-in fans to ensure forced air cooling. Air ducts and

optional filters must be designed to allow the air flow described in chapter 6. The

ambient temperature must not exceed the values described in chapter 6. The

ambient temperature is measured by the ELC and will be stored within the

internal error memory.

3.1.1 Mounting of single ELC

The side surfaces of the housing contain 2 T-slots each. Fig. 1 indicates the relative interspace

of the two T-slots and distance to the outer face of the housing. The T-slots are suitable for

sliding blocks 6mm groove, M5 by Bosch Rexroth, as well as for sliding profiles (see Fig. 2) ,

the latter applicable for X6 and higher power, both available as accessories. Fig. 3 shows the

horizontal mounting orientation including the minimum spacing at the back of the ELC.

Alternatively the ELC may be mounted flush with the rear panel if a cut out for the ventilation

is ensured.

Fig. 1: Position of the T-slots

Fig. 2: Sliding profile



3 Installation page 5

ELC X-Series-V1.5-06.18-GB subject to technical alterations

Fig. 3: Mounting of the ELC, horizontal orientation

3.1.2 Mounting in a stack

Up to 12 ELC may be mounted on top of each other. To fasten the ballasts onto each other a

custom-built stacking connector has to be used (available as accessories):

Fig. 4: Stacking connector for stack mounting

3 Installation page 6

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2 Connection

To gain access to the electrical contacts the front hood has to be removed. Loosen the

screwing (according to model 4 or 6 x TX20-screw) and detach the front hood.

The following paragraphs describe the electrical connections.

3.2.1 Connection overview of ballast types X4 – X8

Fig. 5: Overview of electrical connections X4-X8

Cable gasket

X100

X600

X2

X1

X3

X805

X806

3 Installation page 7

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2.2 Profile of the cable gasket X4 – X8

The IP protection level given in chapter 6 is only guaranteed if every cable’s lead-in is

completely sealed.

For this purpose the following preconditions have to be fulfilled:

 Use cables of the nominal diameters given in Table 1.

Cable gasket

Cable

diameter

Connector

designation

Function

Connector

no. of pins

Connector

type eta

ID.:

Cable

length

(gasket to

connector)

Plug

contact

7.5mm

±5%

X3

Bus out

(T-

coupler)

3

9546

120mm

blank

wire or

ferrule

9.3mm ±

5%

X600 (1, 3)

Lamp

output

3

9532

155mm

blank

wire or

ferrule

4.9mm ±

5%

X600 (2)

PE

5.2mm ±

5%

X806

Control

7

9535

130mm

ferrule

7.5mm ±

5%

X1

Bus in

4

9545

120mm

blank

wire or

ferrule

6.7mm ±

5%

X805

Control

11

9536

130mm

ferrule

7.5mm ±

5%

X2

Bus out

4

9545

120mm

blank

wire or

ferrule

12.2mm ±

5%

X100

Mains

input (2 x

Phase, 2 x

PE)

4

9531

490mm

blank

wire or

ferrule

Table 1: Cable connection parameters X4-X8

3 Installation page 8

ELC X-Series-V1.5-06.18-GB subject to technical alterations

 Place the cables into the rubber

surrounds and fix them onto the clamp

with cable straps:

 Slide the front hood onto the sealing lip

and pay attention to a tight connection of

the front hood.

 If the control concept requires fewer

control and bus cables the holes of the

rubber surround have to be sealed with

blank plugs (available as accessories):

3 Installation page 9

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2.3 Overview power connections X4 – X8

Fig. 6: Power connection X4-X8

Fig. 6 shows the electrical wiring. Please consider the following aspects:

Voltage balancing: on installing several ELCs the ballasts have to be equally distributed on all

phases (e.g. 1st ballast L1/L2, 2nd ballast L2/L3, 3rd ballast L3/L1 etc.).

Protective conductors: to ground the ballast it is strongly recommended to connect to X100 at

least one PE-line with a cross section of 10mm² or two PE-lines with nominal cross section of

the mains supply lines.

Cut-Out and loop impedance: The installation of an automatic cut-out is required for line

protection. It is necessary to check the loop impedance afterwards.

Using an RCD: if a RCD is required we recommend a RCD type B. When using a RCD consider

the leakage current given in chapter 6.

Shielding:

The lamp feeder cable shielding must be connected to the ELC at the designated

shield clamp, see paragraph 3.2.9.

If desired, the shielding can also be connected to the lamp unit.



3 Installation page 10

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2.4 Connection overview of ballast types X12 – X36

Fig. 7: Overview of electrical connections X12-X36

3.2.5 Overview profile of the cable gasket X12 – X36

The IP protection level given in chapter 6 is only guaranteed if every cable’s lead-in is

completely sealed.

For this purpose the following preconditions have to be fulfilled:

 Use cables of the nominal diameters given

in Table 2 on page 11. For the mapping to

the lead-ins in the cable gasket see Fig. 8.

 The gasket provides alternative lead-ins for

the use of several cable types.

Fig. 8: Profile of the cable gasket X12-X36

Mains connection

Control connections

Lamp

connection

Cable gasket

4

3

2

1

5

6

7

8

9

10

11

12

13

3 Installation page 11

ELC X-Series-V1.5-06.18-GB subject to technical alterations

Position

(see

Fig. 8)

Cable

diameter

Connector

designation

Function

Connector

no. of pins

Connector

type eta

ID.:

Cable

length

(gasket to

connector)

Plug contact

1

6.8mm ±

5%

X806

Control

7

9535

130mm

ferrule, stripping

length 7mm

2

6.8mm ±

5%

X805

Control

11

9536

130mm

ferrule, stripping

length 7mm

3

7.5mm

±5%

X3

Bus out

(T-coupler)

3

9546

120mm

blank wire or

ferrule, stripping

length 9mm

4

7.5mm ±

5%

X1

Bus in

4

9545

120mm

blank wire or

ferrule, stripping

length 9mm

5

7.5mm ±

5%

X2

Bus out

4

9545

120mm

blank wire or

ferrule, stripping

length 9mm

6

9.8mm ±

5%

X806

Control

(alternative)

7

9535

130mm

ferrule, stripping

length 7mm

7

9.8mm ±

5%

X805

Control

(alternative)

11

9536

130mm

ferrule, stripping

length 7mm

8

13.5mm ±

5%

X600 (1, 3)

Lamp

output

2

-

155mm

blank wire or

ferrule stripping

length 15mm,

direct connection

on board

9

9.3mm ±

5%

X600 (1, 3)

Lamp

output

(alternative)

2

-

155mm

blank wire or

ferrule stripping

length 15mm,

direct connection

on board

10

5.4mm ±

5%

X600 (2)

PE

1

-

155mm

Blade receptacle

6.3mm, direct

connection on

board

X100 (1)

Mains input

PE

(alternativ)

1

9531

490mm

blank wire or

ferrule, stripping

length 18mm

11

5.4mm ±

5%

X100 (2)

Mains input

phase

(alternativ)

1

(9531)

490mm

blank wire or

ferrule, stripping

length 18mm

12

5.4mm ±

5%

X100 (4)

Mains input

phase

(alternativ)

1

(9531)

490mm

blank wire or

ferrule, stripping

length 18mm

13*

12.0mm ±

5%

X100

Mains input

(2 x phase, 2

x PE)

4

9531

490mm

blank wire or

ferrule, stripping

length 18mm

14.6mm ±

5%

Table 2: Cable connection parameters X12-X36

3 Installation page 12

ELC X-Series-V1.5-06.18-GB subject to technical alterations

 Place the cables into the rubber

surrounds and fix them onto the clamp

with cable straps:

 On delivery the lead-ins are sealed with

blank plugs (see Fig. 9). These can be

removed as required.

Note to the lead-in of mains supply (cf.

position 13 in Fig. 8 and Table 2):

When using mains supply cables of

maximally possible diameter the

according blank plug of the blank plug

line has to be removed.

In case of smaller diameter use the

sealing ring of Fig. 9 and put the cable

through it.

Fig. 9: Blank plug line with sealing ring for ELC

X12-X36

 Slide in the front hood centrically into

the sealing lips and pay attention to a

tight connection of the front hood.

3 Installation page 13

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2.6 Overview power connections X12

Fig. 10: Power connection X12

Please consider the following aspects:

Voltage balancing: on installing several ELCs the ballasts have to be equally distributed on all

phases (e.g. 1

st

ballast L1/L2, 2

nd

ballast L2/L3, 3

rd

ballast L3/L1 etc.).

Protective conductors: to ground the ballast it is strongly recommended to connect to X100 at

least one PE-line with a cross section of 10mm² or two PE-lines with nominal cross section of

the mains supply lines.

Cut-Out and loop impedance: The installation of an automatic cut-out is required for line

protection. It is necessary to check the loop impedance afterwards.

Using a RCD: if a RCD is required we recommend a RCD type B. When using a RCD consider

the leakage current given in chapter 6.

Shielding:

The lamp feeder cable shielding must be connected to the ELC at the designated

shield clamp, see paragraph 3.2.9.

If desired, the shielding can also be connected to the lamp unit.



3 Installation page 14

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2.7 Overview power connections X16 – X36

Fig. 11: Power connections X16 – X36

Please consider the following aspects:

Connecting the lines: The Slave module has only to be connected to power supply including

PE on X100. The Master module has to be connected to power supply and PE on X100, and

additionally to all bus-, control- and lamp cables.

Voltage balancing: on installing several ELCs the ballasts have to be equally distributed on all

phases (e.g. 1

st

ballast L1/L2, 2

nd

ballast L2/L3, 3

rd

ballast L3/L1 etc.).

Protective conductors: to ground the ballast it is strongly recommended to connect to X100 at

least one PE-line with a cross section of 10mm² or two PE-lines with nominal cross section of

the mains supply lines.

Cut-Out and loop impedance: The installation of an automatic cut-out is required for line

protection. It is necessary to check the loop impedance afterwards.

Using an RCD: if a RCD is required we recommend a RCD type B. When using a RCD consider

the leakage current given in chapter 6.

Shielding:

The lamp feeder cable shielding must be connected to the ELC at the designated

shield clamp, see paragraph 3.2.9.

If desired, the shielding can also be connected to the lamp unit.



3 Installation page 15

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2.8 X100: Mains connection

X4-X8: Fix the mains connection cables within the cable holder beneath the heat sink with

cable straps. The cables have to be laid behind the control connectors to reach the cable

gasket.

X12-X36: Fix the mains connection cables within the cable holder with cable straps. The

cables have to be laid beneath the board to reach the cable gasket.

Pay attention not to pinch the cables when closing the front hood.



L1

PE

L2

PE

3 Installation page 16

ELC X-Series-V1.5-06.18-GB subject to technical alterations

3.2.9 X600: Connecting the lamp feeder cable

The lamp feeder cable must correspond with the cable parameters described in

chapter 6.

X4-X8 use a plug for the connection:

PE may be collected of pin 2 of the

connector in order to earth the lamp

housing. If the lamp-housing is earthed

otherwise, the pin has to be left open.

X12-X36 lamp feeder cables are connected directly on the board:

Schematic of lamp connection X12-36

Example of X24 master board (delivery

state)

Connector order:

M1 (reserved for internal wiring) - Out1 – Out 2 - M2 (reserved for internal wiring)

PE



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