Metz Eta Plus ELC PE22B Series, Technical Documentation Manual

Page 1: ...GIE Technical Documentation ELC PE22B ELC PE35B eta plus electronic gmbh Lauterstraße 29 72622 Nürtingen Telefon 49 7022 6002 80 Fax 49 7022 65854 E mail info eta uv de www eta uv de Eingetragen unter HRB 724321 AG Stuttgart USt Id Nr DE 146267800 Geschäftsführer Uwe Uhlemann ...

Page 2: ...ELC PE22B PE35B V1 0 05 19 GB Subject to technical alterations ELC Electronic Lamp Control is a registered trademark of IST Metz GmbH ...

Page 3: ...s 6 3 2 1 Mains connection 7 3 2 2 Connecting the lamp feeder cable 7 3 3 Control and bus connections 10 3 3 1 Mounting of the strain relief 10 3 3 2 Connecting bus cables 10 3 3 3 Coding and pin assignment 12 3 4 Comments on the safety functions of the ELC 16 3 4 1 Safety relay 16 3 4 2 Initialisation signal 16 3 5 Configuration 17 3 5 1 Setting up the PROFIBUS address 18 3 5 2 Checking the PROFI...

Page 4: ...on 25 4 6 Standby operation 25 4 7 Use of the control outputs Digital I O 26 4 7 1 User Register 26 4 7 2 DO3 external fan control 27 4 8 Switching off the lamp 27 Monitoring warning error repair 28 5 1 Mains voltage monitoring 28 5 2 Earth fault control 28 5 3 Warning messages 30 5 4 Error 32 5 4 1 Error messages 32 5 4 2 Error description and trouble shooting 33 5 4 3 Resetting the error registe...

Page 5: ...bserved 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 and starting up may only be carried out by skilled electricians Do not open...

Page 6: ...se threshold or by means of an independent equipotential connection 1 3 Correct operation The ELC is an electrical unit intended to be installed in the switch cabinets of industrial high voltage power installations It is conceived as an electronic ballast for the operation of lamps intended for this purpose Any other use is deemed as misuse The manufacturer will not assume liability for damage res...

Page 7: ...dvantages 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 10 do not affect lamp power Ignition device When the l...

Page 8: ...nimum spacing 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 flow of cool air for the ELC must be safeguarded The ambient temperature must not exceed the values prescribed in chapter 6 Ventilation must be provided for the switch cabinet The amount of air neces...

Page 9: ...3 Installation page 5 ELC PE22B PE35B V1 0 05 19 GB Subject to technical alterations 3 1 1 Vertical installation position Fig 1 Assembly of the ELC vertical installation position all dimensions in mm ...

Page 10: ...tallation Operation of the ballasts requires a power choke in series see technical data chapter 6 in order to limit the total harmonic distortion of the line current to below 50 The lamp feeder cable shielding must be connected to the ELC To this end the connector has an EMC screw connection also see connection lamp cable If wished the shielding can also be connected to the lamp unit Mains supply ...

Page 11: ...oid damaging the terminal pins please do not exceed the following torques PE22B Line Torque L1 L2 L3 1 5 1 8 Nm Grounding conductor PE 3 0 4 0 Nm PE35B Line Torque L1 L2 L3 2 0 2 3 Nm Grounding conductor PE 2 0 2 3 Nm 3 2 2 Connecting the lamp feeder cable The lamp feeder cable must correspond with the cable parameters described in chapter 6 Components of the connector connector module hood crimp ...

Page 12: ...e contact crimping tool is required of the type Amphenol group C146 Part No VN01 025 0029 1C Closed crimp barrels individual contacts 2 5mm Top Correct crimp connection Middle Stripped part of the wire too long gap between insulation and crimp barrel too large Bottom Stripped part of the wire too short because conductor is not visible through inspection hole Insert cable into the cable gland and b...

Page 13: ...ly covers the plastic inset of the cable gland 360 contact Tighten EMC cable gland Screw the module into the hood casing The picture on the left shows the recommended orientation The lamp feeder cable between the switch cabinet and lamp assembly must be laid protected For the correct installation of the lamp assembly and lamp please observe the corresponding manufacturer s instructions ...

Page 14: ...not remove the two bolts holding the strain relief They are also fastening the board inside the ballast which might get out of position In addition they are specifically designed to provide a large surface for optimum contact of the strain relief to the housing Attention if it is necessary to prolong the bolts exercise extreme caution when mounting additional parts The built in bolts have a thread...

Page 15: ...shield to appropriate lengths Insulate the shield with a heat shrink tube The tube on the main wire should overlap the shield s tube Mount ferrules and insert the wires into the plug For the plug coding and pin assignment see paragraph 3 3 3 Plug in and tighten the screws of the plug Attach the bus cable to the strain relief with a cable strap The bare shield must have contact with the strain reli...

Page 16: ...In order to minimise the danger of mixing up the control plugs the sockets on the appliance have been coded with the red code profiles They are positioned according to the following picture Fig 4 Coding of the control plug When the control plugs are delivered they are not coded and cannot be connected in this condition In order to code the control plugs the corresponding code nose must be removed ...

Page 17: ... X6 2 X6 3 X6 4 Fig 5 Pin assignment for control of ELC PE22B PE35B Pin assignment of initialisation signal Pin assignment of safety relay Designation Number Description technical INIT PIN X1 1 Input initialisation signal for safety shutdown 24Vext 24V DC 10 external supply input resistance 4 7kΩ max current consumption 5 1mA INIT GND X1 2 GND Reference potential for X1 1 Designation Number Descri...

Page 18: ...er Description technical BUS VCC X3 1 external supply voltage 5V isolated for PROFIBUS 5V DC isolated output for terminator BUS B X3 2 Data line PROFIBUS B Bus signal B BUS A X3 3 Data line PROFIBUS A Bus signal A BUS GND X3 4 GND isolated for PROFIBUS Shield connection PROFIBUS BUS VCC X4 1 external supply voltage 5V isolated for PROFIBUS 5V DC isolated output for terminator BUS B X4 2 Data line ...

Page 19: ...ports for internal purposes RS232 Service TxD X5 2 Service RxD X5 3 n c X5 4 Not connected DO DI 1 X6 1 Open collector output control via USER register of the PROFIBUS output data 24V 10 max 300mA sink DO 2 X6 2 Open collector output control via USER register of the PROFIBUS output data 24V 10 max 300mA sink DO 3 X6 3 Open collector output internally controlled e g for control of an external fan 2...

Page 20: ...relay contact It may be tapped on pins X2 1 and X2 2 the Warning Register of the PROFIBUS input data see below and paragraph 5 3 Bit 4 Safety Relay Open If the safety relay is deactivated during lamp operation lamp operation will be shut down After reactivating the safety relay the lamp has to be restarted 3 4 2 Initialisation signal Furthermore lamp operation will not be allowed unless 24V are ap...

Page 21: ...to Big Endian The preset baud rate is recognized automatically by the ELC Software supports all baud rates from 9 6 kBit to12 MBit tested values can be taken from the technical data in chapter 6 limitations may be caused by the connector The necessary adjustments during the installing of the ELC will be explained in this paragraph the adjustments for lamp operation will follow in chapter 4 PROFIBU...

Page 22: ...ecking the PROFIBUS connection The Status LED Fig 7 may be used to check the successful connection of ELC and Master and furthermore the existence of an error ELC not ready for operation LED green left LED red right Status Corrective action on off ELC ready for operation PROFIBUS connection ok blinking off ELC ready for operation no PROFIBUS connection Check plug contact bus termination see paragr...

Page 23: ... Control characteristic The lamp power can be set in steps of 32 W The ELC s nominal power is written into the register ELC Nominal Power of the PROFIBUS input data PROFIBUS input data ELC Master Byte No 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name ELC Serial Number Software Version ELC Nominal Power Error Register Warning Register Lamp Status Actual Power Actual Voltage Actual Current Reserved Lamp...

Page 24: ...er of the ELC Fig 9 Limited output power characteristic The control characteristic of Fig 8 comes into effect if the register Installed Lamp Power is not set below 20 of ELC nominal power above ELC nominal power Sollleistungs vorgabe Power Set Value Lamp power Installed Lamp Power ELC nominal power 20 ELC nominal power 20 ELC nominal power Installed lamp power Power Set Value ELC nominal power Sol...

Page 25: ...egister Lamp Status Actual Power Actual Voltage Actual Current Reserved Byte 2 Byte 1 Byte 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 ELC Serial Number is indicated by the first three registers The exact division of the bits into year month and consecutive number is defined by the brackets Example 01F305_hex stands for consecutive number 62 month 6 and year 5 Software Version contains the c...

Page 26: ...own below an ambient temperature of 62 C However to keep the internal ELC temperatures on a constant level the maximum output power is decreased by 1 5kW C beyond the maximum operating temperature 0 5 10 15 20 25 30 35 40 0 5 10 15 20 25 30 35 40 45 50 55 60 65 max lamp power kW ambient temperature C max operating temperature temperature derating ...

Page 27: ...ted leakage currents may arise on the electrolytic capacitors which could damage the ELC in the worst case Preventive measure To reform the electrolytic capacitors apply the mains voltage of 3x400V for 1 minute without starting the lamp The ELC is switched on by applying the mains voltage 4 3 Activating the safety circuits Activate the safety relay Apply the initialisation signal 4 4 Switching on ...

Page 28: ... longer period of time and after approximately 60 seconds rapidly increases to its nominal power The lamp is operated with increased current until the nominal power is reached The actual condition of the lamp may be read out from register Lamp Status of the PROFIBUS input data PROFIBUS input data ELC Master Byte No 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name ELC Serial Number Software Version ELC N...

Page 29: ...tely adjusted Enter the desired power in Watts in register Power Set Value A set value of less than 20 of the ELC nominal power will automatically be increased by the ELC to 20 of the ELC nominal power 4 6 Standby operation During longer idle times the ELC can be switched to standby operation The lamp is operated at minimum power but can be brought up to nominal power within a few seconds Standby ...

Page 30: ...connector X6 is pulled to ground if set to 0 the output is high impedance The DO2 bit functions accordingly for output DO2 PROFIBUS output data Master ELC Byte No 0 1 2 3 4 5 Name Power Set Value Installed Lamp Power Lamp Control User Register Bit 7 6 5 4 3 2 1 0 Name n a n a n a n a n a DO2 DO1 n a Example In case of a PE35B cabinet the outputs are used as follows DO1 is connected to the cabinet ...

Page 31: ...s is set 0 After a delay time of 30s the output DO3 is set to 24V As soon as the lamp extinguishes register Lamp Status is reset to 0 After a follow up time of 60s the output DO3 will be reset to 0V Fig 10 Flow diagram of lamp status and DO3 4 8 Switching off the lamp The lamp is switched off by setting the Start Lamp bit to 0 in register Lamp Control In order to avoid heat accumulation in the ELC...

Page 32: ...f the ELC lamp circuit represents another monitoring function Lamp R_error Error Register PROFIBUS connection Earth Fault Bit Fig 11 Earth fault monitoring An earth fault occurs when the isolation resistance R_error see Fig 11 drops below approx 200 kOhm The ELC will shut down the lamp automatically in case of an earth fault In order for the earth fault control to function properly it is essential...

Page 33: ...ctual Voltage Actual Current Reserved Byte 6 Bit 15 14 13 12 11 10 9 8 Name n a n a Lamp Power Low Supply ZVS Earth Leakage Fault Measure ment Overcurrent Byte 7 Bit 7 6 5 4 3 2 1 0 Name Lamp Voltage High Over voltage Bus Connection Error internal ELC Temperature High n a Mains Voltage Low DC Link Undervoltage In order to avoid an unwanted reaction of the earth fault control during faultless opera...

Page 34: ...Relay Open n a n a Run Up Long Lamp Voltage Low Bit 0 The Lamp Voltage Low bit is set if the lamp voltage falls below its minimum set by the manufacturer This bit will be reset if the lamp voltage exceeds the minimum Bit 1 The Run Up Long bit is set if the warm up of the lamp takes longer than expected Reset occurs as soon as the Start Lamp bit in register Lamp Control is set to 0 the lamp being t...

Page 35: ...p Control is reset Bit 7 The Init Signal Ok bit reflects the status of the Init Pin X1 1 of the initialisation signal see paragraph 3 4 2 Init Signal Ok 1 means 24 V on X1 1 the lamp may be ignited and operated normally Init Signal Ok 0 means 0 V on X1 1 the lamp cannot be operated To render the ELC operational again in case Init Signal Ok 0 the initialisation signal on X1 1 has to be 24V and the ...

Page 36: ...ndent error occurs and must be reset for further lamp operation see chapter 5 4 3 PROFIBUS input data ELC Master Byte No 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name ELC Serial Number Software Version ELC Nominal Power Error Register Warning Register Lamp Status Actual Power Actual Voltage Actual Current Reserved Byte 6 Bit 15 14 13 12 11 10 9 8 Name n a n a Lamp Power Low Supply ZVS Earth Leakage F...

Page 37: ...rature too high No Check ambient temperature and fans of cabinet direction of air current change filter mats Bit 4 0x0010 Internal bit for analysis by the manufacturer No Bit 5 0x0020 Bus Connection Error bus connection fails during lamp operation Additionally the green Status LED see Fig 7 is blinking or completely off as soon as the internal communication of the ELC is interrupted Yes Check bus ...

Page 38: ...nectors must be greater than 10 MΩ No Check lamp wiring and insulation resistance Bit 11 0x0800 ZVS the ELC detects switching losses of the power semiconductors and shuts down to prevent damages Possible causes are cracks in the lamp feeder cable defect lamp connectors or internal problems Yes External reasons might be flashovers in the lamp circuit Check or exclude Bit 12 0x1000 Supply indicates ...

Page 39: ...ontrol Register check e g via the Error Register if error eliminated all error bits are 0 again and after an ELC internal synchronisation time of additional 15 ms the Clear Error bit has to be reset to 0 PROFIBUS output data Master ELC Byte No 0 1 2 3 4 5 Name Power Set Value Installed Lamp Power Lamp Control User Register Bit 7 6 5 4 3 2 1 0 Name n a n a n a n a n a n a Clear Error Start Lamp 5 5...

Page 40: ...2 0 kW 7 0 kW 35 0 kW Type ELC PE22B 440 210 ELC PE35B 440 215 Nominal supply voltage 3 x 440 V Nominal supply current 34 2 A 50 0 A Max supply current 37 6 A 60 9 A Line protection 40 A 63 0 A Mains frequency 50 60 Hz Min mains voltage shut down voltage 360 V 396 V Abs max mains voltage 484 V 484 V Leakage current 3 mA see chapter 1 Safety Insulation resistance between primary and PE approx 22 MΩ...

Page 41: ...wer 22 kW 35 kW Nominal lamp voltage 2100 V 2150 V Tolerance lamp voltage nominal voltage 5 nominal voltage 5 Threshold voltage of lamp voltage low warning bit 1050 V 1000 V Ignition voltage period approx 3200 V_rms 1 s 3 trials approx 2700 V_rms 1 s 3 trials Type ELC PE22B 440 210 ELC PE35B 440 215 Article no 8067 U0 U 2 3 4 kV 2x2 5 mm external Ø 13 5 mm 5 30 m 5 40 m Type ELC PE22B 440 210 ELC ...

Page 42: ...B 440 210 ELC PE35B 440 215 Permissible humidity 95 Permissible pollution pollution severity 2 according to VDE 0110 Ambient operation temperature 0 C to 55 C Ambient storage temperature 20 C to 70 C during storage and transportation before initial operation leave at least 4 hrs at room temperature Maximum storage period 2 years also see paragraph 4 2 Recommended air throughput for cabinet ventila...