OSRAM POWERTRONIC User Manual

www.osram.dewww.osram.

de

www.osram.com/powertronic

Technical Application Guide

®

POWERTRONIC

CONTENTS

Contents

Electronic control gear for metal halide lamps and high­pressure sodium vapor lamps have increased substantially
in importance in the last few years and now represent the
current state of technology.

This technical guide highlights the properties of the elec­tronic control gear and their differences from the conven­tional magnetic control gear when in operation. It also pro­vides hints and tips for the correct installation and opera­tion of the devices according to the applicable standards.
Furthermore, it offers guidelines to the luminaire design,an
overview of the important standards and certifi cations, as
well as the links to the relevant OSRAM websites for elec­tronic control gear. This guide is meant to provide a fi rst
orientation and not to replace one's own expert check.

2

CONTENTS

Contents

1. The system HID lamp and ECG 5

1.1. High-pressure discharge lamps 5

1.2. The POWERTRONIC

®

ECG 5

1.2.1. Product range 6

1.2.2. Operating principle 6

1.2.3. Benefi ts of the intelligent POWERTRONIC

®

ECG 6

1.2.4. Advantages of electronic control gear over conventional gear 6

1.2.5. Application areas 7

1.2.5.1. Indoor, outdoor 7

1.2.5.2. Installation of devices in luminaires or mounting the types

with cable clamp in suspended ceilings 8

2.2.4. Wiring 13

2.2.4.1. Wire and cabling types 13

2.2.4.2. Cabling cross-section 13

2.2.4.3. Cable length between ECG and lamp 13

2.2.4.4. Cable layout 14

2.2.4.5. Wiring plans for integration of POWERTRONIC

2.2.4.6. Wiring plans for downlights with POWERTRONIC

with cable clamp 15

2.2.4.7. Wiring plans for POWERTRONIC

®

2.2.4.8. Stripping length 16

2.2.5. Inrush current limiter 16

2.2.6. Leakage current, protective current, contact current,

2. The product in operation 9

2.1. Supply voltage 9

2.1.1. Permissible voltage range 9

2.1.2. Overvoltage > 264 V 9

2.1.3. Undervoltage > 198 V 10

2.1.4. DC voltage 10

2.1.5. ECGs for networks with 120 V/277 V 10

2.1.6. Operation on a three-phase network 10

2.1.7. Overvoltage protection 11

2.2. Installation 11

2.2.1. ECG operation for luminaires with protection class I and II 11

2.2.2. Insulation 11

2.2.2.1. Insulation distances in luminaires 11

2.2.2.2. Insulation testing in luminaires 11

2.2.2.3. Insulation resistance in lighting installations 12

2.2.3. Output voltage 12

2.2.3.1. Lamp ignition voltage 12

2.2.3.2. Operating voltage (U-OUT) 12

earth leakage circuit breaker (ELCB) 17

2.3. Behavior in operation 17

2.3.1. Lamp ignition and lamp operation 17

2.3.2. Hot restrike of lamp 17

2.3.3. ECG reset, restart 17

2.3.4. Constant lamp wattage 17

2.3.5. Power factor, compensation 18

2.3.6. ECG temperatures and their effect on service life 18

2.3.6.1. Device temperature t

2.3.6.2. Ambient temperature t

19

c

of ECG 19

a

2.3.6.3. ECG self-heating 19

2.3.6.4. Practical assessment of the service life and

thermal properties of an ECG 20

2.3.6.5. Effect of temperature on service life 21

2.3.6.6. Failure rate 21

2.3.7. General hints on installation in relation to temperature 22

2.3.7.1. Power reduction control due to overtemperature 22

2.3.7.2. ECG temperature measurement in luminaires 22

2.3.8. The ECG's ability to withstand frequent on/off switching 23

2.3.9. Short-circuit strength 23

2.3.10. Switch-off criteria and mechanisms 23

2.3.10.1. Monitoring lamp voltage 23

2.3.10.2. Ignition time limitation 23

2.3.11. Lamp shutdown at end of life 23

2.3.12. Noise levels 24

2.3.13. Dimming 24

®

ECG PTi and PT-FIT 14

®

ECG

ECG PTo 16

3

CONTENTS

Contents

2.4. Hints on luminaire design 28

2.4.1. Thermal coupling 28

2.4.2. Ventilation slits, cooling fi ns 28

2.4.3. Materials that can be used in luminaire structures 28

2.4.4. Installation-friendly ECG 28

2.4.5. Installation space for independent devices 30

2.4.6. Plug-&-Play installation with cable/socket system 30

2.4.7. Passing network cabling through via

"fl oating" terminal 30

2.4.8. Lamp sockets that may be used 30

2.4.9. Protection against electrostatic build-up in outdoor luminaires 31

2.4.10. Protection against moisture in outdoor luminaires 32

2.5. Electromagnetic compatibility 32

2.5.1. Specifi ed harmonic limits 32

2.5.2. Resistance to interference, immunity 32

2.5.3. Radio interference 33

2.5.3.1. Causes of radio interference 33

2.5.3.2. Hints on installation to prevent radio interference 33

2.6. Errors, causes and solutions 34

4. ECG label 39

+

5. The System

6. Further information 40

7. Glossary of key words 41

guarantee 40

3. Standards, quality marks and CE labeling 35

3.1. Standards 35

3.1.1. Safety 35

3.1.2. Electromagnetic compatibility (EMC) 35

3.2. Quality marks 37

3.2.1. The VDE label 37

3.2.2. The ENEC mark 37

3.2.3. The VDE EMC mark 37

3.2.4. The CCC/CQC mark 37

3.2.5. The C-tick/RCM mark 37

3.2.6. The GOST mark 37

3.3. The CE marking 38

3.4. Energy effi ciency certifi cation 38

3.5. Other certifi cations 38

4

THE SYSTEM HID LAMP AND ECG

1. The system HID lamp and ECG

1.1. High-pressure discharge lamps

Metal halide lamps and high-pressure sodium vapor lamps
both belong to a group referred to as high-pressure dis­charge lamps. In contrast to what happens in low-pressure
discharge, the discharge tube in such lamps operates at
high temperatures and pressures. The light in discharge
lamps is generated in a gas discharge that takes place in
the arc tube between two electrodes after ignition. In the
case of high-intensity discharge lamps, the arc tube is ge­nerally housed in an evacuated outer bulb, which thermally
insulates the hot arc from the environment in a similar way
to the principle used in a thermos fl ask. However, there are
also discharge lamps that do not have any outer bulb, and
also ones with an outer bulb fi lled with gas.

During gas discharge, the metal halide additives and mer­cury or calcium amalgam are excited by the fl ow of current
and emit excitation energy in the form of the radiation
characteristic of each of the elements it contains. The
mixture of different radiation components produces the
desired color temperature and color rendering properties.

OPERATION MODE OF A HIGH-PRESSURE DISCHARGE LAMP

Discharge

UV Filter Outer bulb

(Quartz)

Molybdenum
Foil

Arc Tube

(Quartz)

Heat

Lead-in

arc

Reflector

wire

Base

They are also often called MH (Metal Halide) lamps.
Metalhalide lamps are principally characterized by
the following properties:

• Good luminous effi cacy

• Long service life

• Very good color quality

• Good to very good color rendering

• Point light source, with benefi ts in light control
and lighting brilliance

More detailed information on metal halide lamps can be
found in the following application guide: "Metal halide
lamps – hints on application and use"

Sodium vapor lamps are also referred to as HS
("High-pressure Sodium") lamps. They are principally
charac ter ized by the following properties:

• Optimal energy effi ciency

• Long service life

• Good reliability

• Very high luminous effi cacy

• Very good lumen maintenance

• Good dimming behavior

Contact
Plate

Figure 1: Structure of a quartz burner

Halides ElectrodeMercuryGetter

Metal

Molybdenum
Foil

The illustration above shows the structure of a metal
ha lide lamp as an example of a double-ended lamp with
aquartz burner.

Metal halide lamps and high-pressure sodium vapor lamps
are also referred to as HID lamps, which stands for High
Intensity Discharge lamps.

Metal halide lamps can also be referred to as HIT lamps
(using the "LBS" lamp designation system):

H: High-pressure
I: Iodide
T: Tubular

More information on sodium vapor lamps can be found in
the following application guide: "High Intensity Discharge
lamps"

1.2. The POWERTRONIC

®

ECG

Electronic control gear (ECGs) for the operation of metal
halide lamps with ceramic (HCI) or quartz burners (HQI)
orsodium vapor lamps (NAV) are all referred to using the
term POWERTRONIC

POWERTRONIC

®

at OSRAM.

®

ECGs replace all the conventional
system components of a luminaire (choke, ignition unit
and correction capacitor), thus making the assembly
substantially simpler. Other benefi ts include the ability to
optimally operate the lamp so as to maximize the lamp
service life and minimize the lumen loss.

Electronic control gear has become the right choice for
operating metal halide lamps with ceramic burners, as its
technical properties are able to make the most of thefull
potential of such lamps.

5

THE SYSTEM HID LAMP AND ECG

1.2.1. Product range

POWERTRONIC
wattages. For indoor applications, the PTi and PT-FIT
control gear (POWERTRONIC

®

ECGs are available in a variety of

®

indoor) have been devel­oped for operation of HCI and HQI lamps. For this area
ofapplication there are ECGs available that are capable
ofbeing connected to one or two lamps. PTo control
gear(POWERTRONIC

®

outdoor) have been developed

foroutdoor operation of HCI, HQI and NAV lamps.

1.2.2. Operating principle

In POWERTRONIC

®

ECGs for high-pressure discharge
lamps, all functions for lamp ignition, lamp operation,
including monitoring and lamp shutdown are controlled
byasingle device.

In order to achieve optimal lamp operation, POWERTRONIC
ECGs convert the sinusoidal alternating voltage from the
mains supply into a square-wave voltage with an operating
frequency of between 100 and 240 Hz. For optimal lamp
ignition, up to 4.5 kV is supplied by the ECG. Butthat will
not allow the restrike of hot lamps.

The following diagram shows the current and voltage
curves at the output end of a 150-W POWERTRONIC

®

square wave ECG:

200 4.0

160 3.2

120 2.4

-40 -0.8

Voltage (V)

-80 -1.6

-120 -2.4

-160 -3.2

-200 -4.0

Figure 2: 150 W POWERTRONIC® square-wave ECG

Voltage
Current

80 1.6

40 0.8

0 0

67891011121314151617181920212223242526

Time (ms)

Current (A)

1.2.3. Benefi ts of the intelligent POWERTRONIC® ECG

The following list shows the main benefi ts of using an
intelligent OSRAM POWERTRONIC® ECG:

• Compact and lightweight

• Long service life of ECG at maximum permissible
temperatures

• Good thermal behavior: High t

and tc temperatures for

a

best possible ECG performance, even in luminaires
where heat is a critical factor

• Micro-controller for fully digital lamp control, intelligent
ignition management and safe shutdown at the end of
the lamp life

• Power reduction control and reversible shutdown of the
ECG in cases of unsuitably high ambient temperature
formaximum light comfort

• Versions with cable clamp, with easy-to-install, two- piece

®

cable clamp (applies to indoor ECGs).

• PCB models for installation with the smallest possible
footprint and/or for thermally critical applications
(applies to ECGs for indoors use)

• 3DIM function (DALI

®

, StepDIM and AstroDIM) for PTo

(outdoor ECGs)

• Lightning strike protection up to 10 kV (for outdoor ECGs)

1.2.4. Advantages of electronic control gear over

conventional gear

In the past, HID lamps were operated almost exclusively
using conventional, ferromagnetic control gear. These
conventional devices are increasingly being replaced by
electronic control gear.

The following table offers an overview of the characteristic
properties of high-intensity discharge lamps andat the
same time shows the substantial advantages ofusing
electronic control gear for operating such lamps over
using CCG.

In the comparison between CCG and ECG, the perfor­mance of the CCG is used as the reference, with a value
of 100. This is also due to the fact thatthe parameters
used to characterize lamps are largely fi xed using CCGs
as a reference.

The following block diagram shows the outline structure of
a classic square-wave ECG in half-bridge topology.

Mains
input

EMC
fi lter

Recti­fi e r

PFC

Control
unit

Figure 3: Block diagram of a square-wave ECG with half-bridge topology

Buck
converter

Half-bridge
inverter

Ignition

6

THE SYSTEM HID LAMP AND ECG

Comparison of CCG and POWERTRONIC

Energy consumption 100 For indoor applications: 10 to 15 % savings over

Lamp life 100

Lamp warm-up Depends on lamp type: generally approx. 60–90 sec,

Color stability (HCI/HQI) Color variation possible Substantially improved color stability; both initially and over the

Shutdown at end of
lamp life

Shutdown of ignition Only with timer-based ignition devices Default shutdown of ignition after 20 minutes

Light fl icker Visible fl icker Flicker-free thanks to operation at 100–240 Hz

Power constancy Increased wattage over the whole service life, wattage also

Usability 3 components, complex wiring 1 device, simple wiring

®

Magnetic control gear (CCG) POWERTRONIC® electronic control gear

the whole service life

For outdoor applications: up to 30 % savings over
the whole service life through dimming function (3DIM)

Up to 30 % depending on lamp type and
application

up to 90 % of nominal luminous fl ux

None or only primitive shutdown mechanisms Continuous parameter control, intelligent shutdown mechanisms

depends on temperature and mains voltage fl uctuations
and cable length

Up to 50 % faster

whole service life

± 3 % over the whole service life, independent of temperature,
mains voltage fl uctuations and cable length

Size and weight Heavy, more components, can be quite large Lightweight and compact

Power factor correction (PFC) 0.5–0.95, substantial fl uctuations due to age ≥ 0.95

Noise generation Possible detectable humming Almost soundless

®

Bi-directional data exchange Not possible Generally possible (DALI

Dimming Possible to a limited extent (additional components necessary) 3 different dimming modes possible for outdoor ECG

Lightning protection Not necessary For outdoor ECG up to 10 kV

The above values and statements are based on research and experience with OSRAM POWERTRONIC
trans ferable on a one-to-one basis to the devices made by other manufacturers.

1.2.5. Application areas

1.2.5.1. Indoor, outdoor

POWERTRONIC

®

PTi and PT-FIT ECGs have been devel-

oped for indoor applications and for these they are suitable.

Any guarantee claims against OSRAM POWERTRONIC
PTi and PT-FIT ECGs are void if they are used in outdoor
areas – no matter what the IP classifi cation of the installed
luminaires may be.

POWERTRONIC® PTo ECGs were developed for deploy­ment in outdoor areas. Due to their robustness, they offer
substantial improvements in the way they deal with out­door weather conditions (e.g. moisture or temperature
changes), vibrations or also transient power supply con-

®

ditions (caused by switching or lightning (EN 61000-4-5
Section 1). Besides street lighting, PTo ECGs can be used
in industrial applications. Both areas of application make
tough demands for surge voltage stability. PTos exceed

®

, StepDIM and AstroDIM)

(DALI

)

®

devices and are therefore not

the standards required for Installation Class 4, with test

PTi and PT-FIT devices conform to the requirements of

levels for L to N of 3 kV and for L/N to PE of 4 kV.
IEC/EN 61547: Resistance to interference under surge
voltage between L and N 1 kV, between L/N and PE 2 kV
for devices with input power > 25 W, with these values
divided by two where power is < 25 W. These levels of
testprecision (test levels) comply with installation classes
2 (< 25 W) and 3 (> 25 W) in accordance with
IEC/EN 61000-4-5 Annex A.

7

THE SYSTEM HID LAMP AND ECG

1.2.5.2. Installation of devices in luminaires or moun t­ing the types with cable clamp in suspended ceilings

POWERTRONIC
ver sions – each tailor-made for the requirements of the
light ing application they are being used in. Thus there
isa basic distinction between:

• ECG for (indoor and outdoor) installing in luminaires

• ECG with cable clamp for mounting independently,

for example, in suspended ceilings (indoors)

®

ECGs are available in two different

Figure 7: PTi SNAP with integrated plug-in system

Figure 4: PTi S or PT-FIT S for installation in luminaires

Figure 5: PTi I or PT-FIT I with cable clamp

Figure 8: PTo for installation in luminaires

HID ECGs for installation in luminaires are each given the

abbreviation "S" in OSRAM terminology. The circuit-board

versions are distinguished with a B (for "Board"). Devices

equipped with a cable clamp are distinguished with an "I"

(for "Independent"), and those with an integrated plug-in

system are marked "SNAP".

ECGs for indoor installation generally have a metal casing

(aluminum or sheet steel) to facilitate the best possible

thermal coupling with the luminaire they are fi tted into.

Devices with cable clamp for independent mounting must

have the following properties:

1.) Protection against electric shock conforming to
IEC/EN 60598-1. An effective option for fulfi lling this
requirement would be to use casings made of non­conducting materials, such as plastic (e.g. polyamide)

2.) Relief of push and pull strains on connection cable

®

It is possible to fasten all POWERTRONIC

PTis to wood,
as it complies with the temperature requirements required
for certifi cation in accordance with VDE 0710-14 and
DINVDE 0100-559. The devices carry the MM mark.

Figure 6: PTi B or PT-FIT B for installation in luminaires

8

THE PRODUCT IN OPERATION

2. The product in operation

2.1. Supply voltage

2.1.1. Permissible voltage range

All POWERTRONIC

®

ECGs for the operation of high-pressure
discharge lamps are designed for sinusoidal alternat ing
voltages at 50 to 60 Hz in a nominal voltage range of
220–240 V. Deviations of -10 %/+6 % from each of the
nominal voltage boundary values are permissible – even
within such a range, thanks to the ECG, lamps will still
remain within the optimal working range set for the
relevant lamp type.

Nominal voltage range and behavior in case of
undervoltage or overvoltage

Nominal voltage range

AC voltage 220–240 V, 50/60 Hz

Permissible voltage range for continuous operation

AC voltage 198-264 V, 50/60 Hz

Behavior with undervoltage

Lamp operation with undervoltage 198–220 V → guaranteed lamp operation

Voltage drop during
operation

Behavior with overvoltage

Lamp operation with overvoltage U : 240–264 V → guaranteed lamp

Voltage peak during
operation

Short transients or impulse voltages
in accordance with EN/IEC 61547.

198 V ≥ U ≥ 176 V → lamp start
and operation usually possible,
but not guaranteed
U < 176 V → unspecifi ed range
→ continuous operation not possible

operation

U > 264 V → continuous operation not
possible, ECG may be irreversibly dam­aged within seconds, depending on the
height of the peak.

®

POWERTRONIC

ECGs are protected

2.1.2. Overvoltage > 264 V

During operation above the nominal voltage range
("overvoltage"), a distinction is made between two forms
of overvoltage which differ in terms of their duration:

Short-term surge voltages that are typically in the micro­second range (fast transient or impulse voltages).

Such surge voltages may be caused by:

• Switching inductive loads (e.g. welding devices,
elevators, inverters, etc.) on or off

• Lightning strikes

POWERTRONIC

®

ECGs are protected against short-term

mains voltage surges in accordance with EN/IEC 61547

Quasi-stationary overvoltage, which may last into the
minutes to hours range.

Such overvoltage may be caused by:

• Imbalances in mains loads (interruption of the neutral
conductor in three-phase networks plus additional
asymmetrical load balancing)

• Unstable supply networks

The strain caused by overvoltage will always exert a heavier
load on each individual component (part). This in turn
leads to heavier thermal loads and can thus have a
nega tive effect on the service life of the affected ECG.

®

POWERTRONIC

ECGs are not suitable for operation
where loading is unbalanced. In extreme cases, overvoltage
can lead to the destruction of the affected ECG. There are,
however, exceptions from these remarks, such as the
PTiSNAP devices (you can obtain details on them in their
various technical datasheets) which exhibit a high level of
stability in load imbalances. Such devices can withstand
overvoltage of up to 300 V for 48 hours and of up to 320 V
for two hours. In the range from 275 < V < 320, these
ECGs shut down after 40 seconds in order to protect their
own circuits from destruction. With mains voltages of over
320V they shut down immediately. Extended periods
withmains voltages > 320 V may lead tothe destruction
ofthe device.

Valid for: The POWERTRONIC

®

ECG

Operation outside of the permissible nominal voltage range
can lead to the ECG being damaged. For this reason, the
layout of the relevant network and its permitted values and
tolerances should be considered when deploying elec tronic
control gear.

9

THE PRODUCT IN OPERATION

2.1.3. Undervoltage > 198 V

The operation of ECGs below the permissible nominal
voltage range ("undervoltage") is not permitted and may
lead to the following effects:

• Lamp operation outside nominal values → Effect on
lamp life

• Uncertain lamp ignition, as ignition is guaranteed only
above 198 V.

• Unstable behavior of lamp, up to and including the lamp
being extinguished

• Overload on the electronic control gear, as the lamp's
own correction mechanisms in low voltages may give
rise to substantially higher operating current.

In extreme cases this may lead to overloading of compo­nents and to the device failing. The following causes may
lead to undervoltage:

• Imbalances in mains loading

• Incorrect electrical installation

• Unstable supply networks

• Transition resistance at electrical connections

2.1.4. DC voltage

DC-capable ECGs are marked with "0 Hz" in technical
information sheets. At present there are no devices in
thePOWERTRONIC

®

ECG product range that fulfi ll the

requirements of DC compatibility.

correct faulty

U

L1

U

N

(e.g. 230 V~)

N

L3

L2

Figure 9: 3-phase network

* > U

U

N

N

phase-Phase

= UN x √3

(z.B. 400 V~)

L1

UN* > U

N

N

L3

L2

Theoretical maximum value:
UN* max = UN x √3 (= 400 V AC @ UN = 230 V AC)
In practice:
UN* < 350 V in most cases
(without fully asymmetrical load balancing)

If the shared neutral conductor is interrupted in an ECG
installation in star confi guration while voltage is present,
then ECG luminaires or groups of luminaires may be ex­posed to unacceptably high voltages (load imbalances)
and the electronic control gear may be destroyed as a result.

2.1.5. ECG for networks with 120 V/277 V

Electronic control gear units for metal halide lamps are now
being increasingly used in North America (the USA and
Canada). OSRAM SYLVANIA supplies a growing number
ofdevices that are usable in North American networks with
120V/277 V and 60 Hz mains frequency.

Further information on this topic is available at:
http://www.sylvania.com/en-us/products/ballasts

Note: The HID ECG family is referred to using the ab­breviation QT xxx MH (for Metal Halide) on the North
American market.

2.1.6. Operation on a 3-phase network

Luminaires and groups of luminaires can be operated in
a3-phase network using a shared N (neutral) conductor.
This graphic shows both the correct (left) and incorrect
(right) wiring and its consequences.

The following points should be observed for electronic
control gear used in 3-phase networks.

1. Check whether the mains voltage is within the per­missible nominal voltage range for the ECG

2. Make absolutely sure that the neutral conductor is
correctly connected to all the ECG fi xtures and that
it is making proper contact.

3. Cables should only be connected or disconnected
when no voltage is present

4. For 3 x 230/240 V supply networks in triangular circuit
arrangements, protection by way of common discon­nection of the phase conductor will be required

Important:

In new systems, users should not connect to the network
when the insulation resistance is being measured at 500 V
DC since, according to IEC 0100 6 Section 9.3, the test
voltage is also applied between the neutral conductor (N)
and all three external lines (L1, L2, L3). In existing systems
it is suffi cient to conduct an insulation test between the
external conductors (L1, L2, L3) and the protective earth
(PE) without disconnecting from the network. The neutral
conductor (N) and the protective earth (PE) must not be
electrically connected in any way while this is being done.
For the insulation measurement (500 V DC to Earth) the
neutral conductor terminal may only be opened after the
mains voltage has been switched off.

Make sure that the N conductor is correctly connected
before putting the equipment into service.

The neutral conductor should never be interrupted during
the operation of the lighting installation.

10

THE PRODUCT IN OPERATION

2.1.7. Overvoltage protection

In conventional three-phase installations, electronic
control gears are generally suited to an input voltage of
between 220 and 240 V.

Depending on the load balance, this value may rise in case
of the missing or unsatisfactory contact of the neutral
conductor to a maximum value of √3 x 230 V = 400 V:

POWERTRONIC® ECGs are not suitable for operation
where loading is unbalanced. In extreme cases, over­voltage can lead to the destruction of the affected ECG.

There are, however, exceptions from these remarks, such
as the PTi SNAP devices (you can obtain details on these
in their various technical datasheets) which exhibit good
surge protection capability (see also chapter 2.1.2).

2.2. Installation

2.2.1. ECG operation for luminaires with protection
Class I and II

Luminaires are classifi ed according to the level of pro­tection against electric shock according to EN 60598-1.

Protection Class I

For luminaires under Protection Class I, all touchable
conducting parts that might become "live" in the event of
a failure must be properly connected with the protective
earth.

®

POWERTRONIC

ECGs are generally suitable for use in
PC I luminaires. To conform to the specifi cation you must
make a correct connection of the PE terminal to the ECG
via the PE connection.

Protection Class II

For Protection Class II luminaires, protection against electric
shock does not depend only on basic insulation, but also
on additional precautions such as additional insulation or
improvements to existing insulation. Protection Class II
luminaires therefore have no protective earth (PE) connection.

®

POWERTRONIC

ECGs have been certifi ed in accordance
with safety standards EN 61347-1 (General safety require­ments) and EN 61347-2-12 (Particular requirements) as
PC I ECG (carrying the protective earth symbol). In addi­tion, EMC approval is also granted at PC I level for ECGs.

However, under certain conditions, these ECGs can also
be used in PC II luminaires (without any PE connection).
The following preconditions must be fulfi lled in such cases:

• Only L and N terminals are available as electrical con-

nection terminals for the luminaire. There is no PE
connection for the luminaire.
=> No protective earth is connected either to the lumi­naire or the ECG.

• The ECG is installed in such a way that either the PE

ECG terminal (marked with the Protective Earth symbol)
or the ECG is not visible and thus cannot be connected
with PE accidentally.

• The requirements in relation to additional or improved
insulation, creep distances and clearances are fulfi lled
for ECGs with cable clamp or ensured using other ap­propriate precautions (adding separations, increasing
distances, etc.) when installing the ECG in the luminaire.

• The EMC requirements are also fulfi lled without connec­ting the PE or ensured by taking appropriate precautions
(using ferrites, etc.).

2.2.2. Insulation

2.2.2.1. Insulation distances in luminaires

When constructing luminaires, the EN 60598-1/IEC 60598-1
standard is decisive in relation to the topic of electrical
safety (especially in terms of contact safety).

In order to ensure the electrical safety of a luminaire creep
distances and clearances between electrical connections
must be considered. These terms are described in
EN60598-1 Section 11 for the supply terminal of the lumi­naire.
"Creep distances at a supply terminal shall be measured
from the live part in the terminal to any accessible metal
parts". The clearance shall be measured between inco­ming supply wiring and accessible metal parts, i.e. from a
bare conductor of the largest section to the metal parts
which can be accessible. At the internal wiring side of the
terminal the clearance shall be measured between live
parts of the terminal and accessible metal parts."

Further information on this topic is available in the
EN60598-1 luminaire standard.

2.2.2.2. Insulation testing in luminaires

Luminaires must be subjected to an insulation and high­voltage test (according to EN 60598-1). This test should
becarried out as follows:

• The supply terminal and all lamp cabling for the lumi­naire – except the protective earth terminal – should
be connected together conductively.

• Apply a test voltage between the connected mains and
lamp cable and the earthed metal parts.

− Test insulation with 500 V DC min. 2 MΩ (corresponding
to a max, 0.25 mA leakage current) will be necessary.

− High-voltage test with 1.5 kV, AC/50 Hz: 1 sec without
fl ashover (e.g. leakage current < 10 mA)

Permissible alternatives in luminaire manufacture are
(PM333, PM 395)

• 100 % high-voltage test (insulation testing may be
dispensed with) or

• 100 % insulation test and 1–2 % high-voltage test or

• Alternative testing in consultation with the test center
(e.g. VDE)

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THE PRODUCT IN OPERATION

2.2.2.3. Insulation resistance in lighting installations

The insulation resistance in lighting installation (> 1.0 MΩ)
must be measured in accordance with IEC 60364-6
Section 61.3.3 between:

• The outside cables (L1, L2, L3) and the protective earth (PE)

• The neutral cable (N) and the protective earth (PE)

In spaces with a higher threat of fi re the insulation resis­tance should also be measured between:

• The outside cables (L1, L2, L3) in relation to each other

• The outside cables (L1, L2, L3) and the neutral cable (N)

The insulation testing should be done at 500 V DC.

Insulation measurement between N/L and PE

The tests should be made both in new and in existing sys­tems. The test intervals for existing systems should be set out
in the relevant workplace or operational safety regulations.

Insulation measurements should be made without the user
disconnecting any connection. The neutral conductor (N)
and the protective earth must not be electrically connec­ted in any way. For the insulation measurement (500 V DC
to PE) the neutral conductor terminal may only be opened
after the mains voltage has been switched off. It is essen­tial that the connection is reestablished securely before
switching the mains voltage back on. Otherwise, load
imbalance and the consequent surge voltage may lead
tothe destruction of all ECGs in the system.
Permissible: 500 V = max. 1 mA measured current

Testing procedure:
The ECG fi rst appears to show low impedance (due to
loading of the capacitors in the interference suppression
fi lters). The ECG then shows high impedance. A short
circuit between the lamp wires does not affect the ECG.

2.2.3.1. Lamp ignition voltage

POWERTRONIC

®

ECGs use asymmetric ignition. For this
reason it is important to mark each lamp connection clearly.
A distinction should be made between the cable carrying
the high-voltage potential (25 kV), which is referred to a the
Lamp High (LH) and the second cable, also known as the
Lamp Low (LL), which has a substantially lower potential
(U-OUT) in comparison with the PE.

LH and LL are marked clearly on the device label.

LH should be kept as short as possible. In addition, with
Edison fi ttings it may be necessary to check that the
potential carrying cable is connected correctly.

2.2.3.2. Operating voltage (U-OUT)

U-OUT is a compulsory ECG marking according to Safety
Standard EN 61347-2-12.
In this context U-OUT indicates the largest effective
working voltage between

• The output terminals

• Each output terminal and the PE
in the normal operation of a high-pressure discharge lamp.
The output working voltage U-OUT is often designated
open circuit voltage.

The above information is important for all components that
are electrically wired or connected between the ECG and
the lamp.

The components such as lamp cables, lamp sockets
(EN60061-2), insulation parts and all other components
that may come into contact with the ECG output terminals
must be designed for the following voltages:

• For the LL connection the U-OUT working voltage

• For the LH connection the ignition voltage

The ECG is not destroyed by the insulation test! A pre­condition for this is that a maximum current value of
1 mA is not exceeded.

Caution:

Before commissioning the lighting installation, check that
N cable connections are in order! The neutral conductor
should never be interrupted while the lighting system is
operating.

2.2.3. Output voltage

During the operation of a high-pressure discharge lamp,
a general distinction is made between the ignition phase
and the normal operation of the ECG. During the ignition
phase some very high ignition voltages up to 4.5 kV may
occur temporarily at the outlet connection. In contrast,
the output voltage, which is measured during normal oper­ation of a high-pressure discharge lamp at both output ter­minals, is never higher than the U-OUT working voltage.

As an ECG manufacturer, OSRAM ensures that no higher
voltage is to be expected at the output terminals than the
ones described above against any other potentials or
against the PE; e.g at the refl ector. For this reason, no
additional voltage reserve need be considered.

12

THE PRODUCT IN OPERATION

2.2.4. Wiring

2.2.4.1. Wire and cabling types

When wiring luminaires in order to use high-pressure
discharge lamps, it is important to consider the U-OUT
voltage on the ECG's label. The U-OUT value gives infor­mation on the types of wiring to be used.

OSRAM POWERTRONIC

®

ECG values indicate a U-OUT
voltage of <430 V. H05 cables for luminaire wiring (on
both the mains and the lamp side) are thus suitable.

If high temperatures are to be expected in the vicinity
ofthe luminaire, then cabling with silicon insulation is
re commended.

As heavy pulse loads of up to 4.5 kV occur during lamp
ignition, high-voltage capable, double insulated cable
should be used on the lamp side.

The capacity of particular types of cabling to deal with
short voltage peaks should be checked with cable manu­facturers. For example cables marked with SiHF J 3x1.5
have been tried and tested positively for lamp side con­nection.

It is not recommended to use simple standard or Tefl on
cables without any additional insulation protection, as
suffi cient insulation between each individual cable strand
cannot be assured over the entire service life of the lumi­naire, thus leaving open the risk of damage to the ECG
orluminaire.

2.2.4.2. Cable cross-section

The cable cross-sections to be used are shown on the
label of the electronic control gear. In general, thefollow­ing values apply.

2.2.4.3. Cable length between ECG and lamp

The length of cables between the POWERTRONIC

®

and

the lamp/luminaire is of decisive importance to:

• The ignition reliability of the system

• Conformity to the EMC limits for the relevant lighting
installation

A reliable lamp ignition must be ensured even in such un­favorable conditions as low ambient temperature or high
humidity. Naturally, it should also be ensured for older
lamps.

A decisive factor in the allowable length of the cable is the
load capacitance of the cable being used. A load capaci­tance of about 80 pF/m may be considered a good rule of
thumb for a standard cable. The exact values should be
obtained from the relevant cable manufacturers.

In cases where longer cabling is required, the following is
recommended:

• Use cables with particularly low capacitance

• Selecting a luminaire structure in which the wiring on
the lamp side exhibits restricted coupling capacitance
with the PE

An overview of the maximum possible load capacitance for
each ECG can be found on its technical datasheet.

Besides reliable ignition, the cable length will have a decisive
infl uence on the EMC behavior of the lighting installation.
Detailed information on this topic can be found in chapter

2.2.4.4 Wiring.

Solid and multi-wire cables:
Wire cross section of 0.5 mm

2

to max. 2.5 mm2 (see tech-

nical datasheet for individual sample types)

The use of cable end sleeves is permissible but not abso­lutely necessary. It should be noted that maximum cross
section applies to wires without cable end sleeves.

The brazing (tin plating) of cable ends has not proved suc­cessful, as a durable stable contact between terminal and
cable cannot be guaranteed if this is done. For this reason
this method is not recommended.

Solid cables can be inserted into the terminal directly, with
fl exible cables you should use the push buttons for con­necting and disconnecting cable strands.

Note on mains connection with fl exible connection cables
(according to EN 60598-1):
In order to ensure suffi cient mechanical stability the nomi­nal cross section of the cable should not be less than:

• 0.75 mm

• 1 mm

2

for ordinary luminaires

2

for other luminaires

13