OSRAM POWERTRONIC User Manual

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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.

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

of ECG 19

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

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

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.

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

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

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.

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

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.

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

(e.g. 230 V~)

Figure 9: 3-phase network

* > U

phase-Phase

= UN x √3

(z.B. 400 V~)

UN* > U

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.

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)

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.

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

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

for ordinary luminaires

for other luminaires

THE PRODUCT IN OPERATION

2.2.4.4. Cable layout

In order to achieve good radio interference suppression and the greatest possible degree of operational safety, attention should be paid to the following points for wiring:

1. Keep the cable between ECG and lamp as short as possible.

2. In order to prevent coupling of lamp lines with mains lines, avoid laying them parallel to each other. The distance between such cabling should be at least 5 cm. Where a crossover is unavoidable, it must be done at right angles.

3. Where it is impossible to avoid laying longer lamp cabling, the two strands (LH and LL) must be twisted.

4. Keep mains cables inside the luminaire short and as far away as possible from the ECG.

5. Very short low-inductive connection of the protective earth to the ECG and to all metallic parts of the luminaire (e.g. its reﬂ ector).

6. For luminaires that do not conform to EMC limits it may be necessary to add a ferrite to both lamp cables. The impedance of the ferrite will depend on the wattage of the device and the luminaire. The higher the wattage, the larger impedance you will need to select. The impedance can be varied by changing the number of twists. Typical ferrite values: 20–70 W → 250 Ω; 100 W–150 W → 400 Ω

7. Unprotected cable transition through metal parts should never be used. They should always be made using additional insulation (insulation tubing, cable-entry grommet, edge protection, etc.).

2.2.4.5. Wiring diagrams for integration of POWERTRONIC

ECG PTi and PT-FIT

Below you will ﬁ nd the wiring diagrams for the one and two-lamp PTi and PT-FIT ECG.

Earth Mains

ECG

Figure 10: PTi and PT-FIT 35 to 150 S and B wiring plan

Earth Mains

ECG

Set-up for ECG installation

ECG installation,

two light sources

During wiring you should observe the rules set out in the EN 60598-1 standard for luminaires, and also any countryspeciﬁ c regulations in their version currently in force.

The luminaire housing or any part of it must never be "abused" as a conductor or in any other way have contact with the mains or lamp conductors (e.g. via bare wires, excessively long stripping lengths, screws projecting from the insulation or by excessively sharp edges on sheet metal). Any such contact is dangerous for people and can lead to the destruction of the control gear.

Question: Are L and N swappable (e.g. for portable luminaires)?

Yes on labeling on the casing ~ Yes on labeling on the casing L, N

(applies to Class II luminaires only)

No on labeling on the casing L, N

(applies to Class I portable luminaires)

Figure 11: PTi 2x35 and 2x70 S wiring plan

Earth

Mains

ECG

Figure 12: PTi 20 S and B, 35 S mini or 35 B mini wiring plan

3.0 kV

Set-up for ECG installation

THE PRODUCT IN OPERATION

2.2.4.6. Wiring plans for downlights with

POWERTRONIC

ECG with cable clamp

The wiring of independent devices has particular requirements, particularly from the point of view of the EMC. Forthis reason the following section is dedi cated to dealing with such applications.

Notes:

• Use short lamp cabling: approx. 0.5 m

• The PE-LUM connection may only be used for earthing

the luminaire.

Downlight set-up

Mains

Figure 13: Wiring plan PTi 35 to 70 I with mains looping

Lum

ECG

Mains

Where longer cables (<1.5 m) are necessary, the PE should be connected to the ECG and from the ECG to the luminaire; the lamp cables must be twisted; ferrites must be installed on the lamp cables.

Mains

ECG

Ferrite core Z>250 Ohm @ 100 MHz, 1 twist

Figure 16: (Sample) Wiring plan for improved EMC behavior

Downlight set-up

Example of looping in a ferrite in order to reduce EMC emissions

Mains

ECG

Lum

Mains

Figure 14: Wiring plan PTi 20 I with mains looping

Mains

ECG

Downlight set-up

Ferrite core (1 twist)

ECG Lamp

Ferrite core (2 twists)

ECG Lamp

Figure 17: Looping in ferrite cores to reduce EMC emissions

Figure 15: PTi 100 and 150 I as well as PT-FIT 35 to 70 I wiring plan

THE PRODUCT IN OPERATION

2.2.4.7. Wiring plans for POWERTRONIC® ECG PTo

The PTo devices

provide 3 different dimming modes;

these are provided under the 3DIM feature.

With the exception of the PTo 35

The ECG must be appropriately wired depending on the dimming mode:

POWERTRONIC® 3DIM ECG

HID lamp

Lamp

Mains cable 50/60 Hz

PTo ECG

HID out

POWERTRONIC® 3DIM ECG

HID lamp

Lamp

Mains cable 50/60 Hz

Figure 20: 3DIM – wiring in AstroDIM mode

PTo ECG

HID out

bus/

DALI DALI® controller

Figure 18: 3DIM – wiring in DALI® mode

POWERTRONIC® 3DIM ECG

HID lamp

Lamp

Mains cable 50/60 Hz

HID out

PTo ECG

Further information on the 3DIM functionality can be found in the 3DIM application guide.

2.2.4.8. Stripping length

The required stripping length of wiring depends on the terminal type used by the ECG. A length of 8.5 to 9 mm or 10 to 11 mm is appropriate, depending on the terminal version. The exact stripping length is given on each ECG.

2.2.5. Inrush current limiter

Due to the initial charging of the storage capacitor responsible for internal power supply, a strong pulse of inrush current occurs on switching on an ECG. This pulse lasts for a very short time (< 1 ms). For this reason, if very many ECGs are switched on at the same time (especially when switching on at a peak in mains voltage) a substantially stronger overall current ﬂ ows for a short time. Therefore appropriate switching and protective devices are necessary to ensure sufﬁ cient current. Themaximum number of ECGs allowed per circuit breaker can therefore be calculated by observing the total maximum inrush current impulse per device and its duration. This value is to be found in the datasheet for each individual POWERTRONIC

ECG.

Further information:

SD control switch

Figure 19: 3DIM – wiring in StepDIM mode

www.osram.com/powertronic

THE PRODUCT IN OPERATION

Easy ways of increasing the number of ECGs per circuit breaker:

• Use of the EBN-OS inrush current limiter

• The use of AC relays for each group with the maximum

permissible number of ECGs. These relays should be connected so that they close as soon as mains voltage is applied. The retardation of the relays will cause the inrush current for the 2nd group to occur with a delay as compared to the 1st group. The switch-on peak current value is thus effectively reduced into a number of smaller successive ﬂ ows.

2.2.6. Leakage current, protective current, contact

current, earth leakage circuit breaker (ELCB)

According to current luminaire standards, the term leakage current includes both the concept of contact current and protective current.

The internal interference suppression ﬁ lter in the ECG and the lamp cable near earthed surfaces cause a leakage current through the earth protection cable in Class I luminaires. The strength of this leakage will depend on the type of the affected device.

All POWERTRONIC

ECGs with a consumption of < 4 A have a substantially lower protective current than the maximum permissible value of 2 mA (rms).

Just like in the case of the inrush current, the protective current limits the number of ECGs to the number that can be operated on a leakage current circuit breaker.

The following solutions can be suggested in order to increase the number of devices:

• Distribute luminaires across 3 phases and use

3-phase RCDs

• Use surge-current-resistant short-delay RCDs

• Use RCDs with 30 mA (where permissible)

• Connect max. 30 ECGs per phase and RCD

The contact current is restricted for all POWERTRONIC ECGs to 0.7 mA

, or 0.5 mA

peak

rms

2.3. Behavior in operation

2.3.1. Lamp ignition and lamp operation

The operation of high-pressure discharge lamps is divided into a start-up phase and a running phase, each of which involve very different behaviors. During the start-up phase a voltage range of 1,800 to 4,000 V (depending on the type of lamp) is required for the initial ignition of a high-pressure discharge lamp. During normal running, voltages of 80 to 140 V are required, depending on lamp type and age.

In order to enable the safe and reliable start-up of the lamp, POWERTRONIC

ECGs provide a short burst of ignition voltage of up to 4.5 kV for lamp start. As the ignition process is asymmetric in structure, the strong potential is supplied through the LH terminal marked with the lightning bolt inside a triangle.

The intelligent POWERTRONIC® ECG monitors each phase of the start-up process and, as soon as the lamp has reached stable operating mode after going through what is referred to as the "breakthrough" stage, reduces the voltage to the required value for normal lamp working.

2.3.2. Hot restrike of lamp

POWERTRONIC

ECGs are not capable of igniting high-

pressure discharge lamps when they are hot.

For example, for a metal halide lamp that requires an ignition voltage of up to 4.5 kV cold, the required voltage will increase to 30 kV in a hot state. Progressive cooling of the lamp will bring this value back down. Depending on the lamp's wattage, the luminaire structure and the cooling conditions for the lamp inside the luminaire, high-pressure discharge lamps return to a level in between 3 and 20 minutes in which they can be ignited once more by the ECG, with the maximum of

4.5 kV available to it.

In order to re-ignite double-ended metal halide and NAV lamps from a hot state, special hot restrike devices and special socket designs are required. In addition to this, theapproval of the lamp manufacturer conﬁ rming the suitabi lity of the lamp is also a precondition for this.

2.3.3. ECG reset, restart

If a POWERTRONIC

ECG should switch off (e.g. due to an ignition timeout, temperature-related cutoff, etc.) then itmust be disconnected from mains power for at least

0.5seconds before it can be switched on again.

2.3.4. Constant lamp wattage

As compared with conventional control gear, a POWERTRONIC

ECG supplies its high-pressure dis charge lamp with constant wattage over the whole of the lamp's service life. The ﬂ uctuation range is within a maximum of 5 %. The increase in the lamp working voltage over the service life of the lamp is regulated via the lamp current supplied by the ECG.

In contrast, with a conventional control gear the system wattage may ﬂ uctuate quite substantially, as it is not possible to regulate the lamp voltage.

For more information on this topic, see also the application paper:

"Metal halide lamps" – hints on application and use"

THE PRODUCT IN OPERATION

2.3.5. Power factor, compensation

For all devices that consume electricity, the power factor λ is the ratio of effective power (P power (P

= U x I). This value is affected both by the phase

Appar

Effect

= U x I

) to apparent

Effect

displacement cos φ between the current and the voltage and by the current distortion ε (deviation from the sinusoidal shape).

/ P

λ = P

Effect

= ε cos φ

Appar

In contrast to conventional control gear (CCG: inductive, 50 Hz), with electronic control gear there is practically no phase displacement present. There is therefore no need for any compensation. However, during the operation of electronic control gear small distortions in the sinusoidal mains current may appear. In general, these distortions are also described by harmonics or overtones.

The harmonic content of the line current is strictly controlled by national and international standards (IEC 61000-3-2). Inorder to conform to these standards, OSRAM electronic control gear units have fully electronic harmonics ﬁ lters built in, which ensure that ε > 0.95 and thus that power factor λ ≥ 0.95. From this point of view ECGs are signiﬁ cantly better than CCGs.

2.3.6. ECG temperatures and their effect on service life

In evaluating the properties of an ECG, considerations relating to their thermal behavior in relation to maximum permissible temperatures are decisive. In this context one should always distinguish between the ambient temperature of the luminaire, the ambient temperature of the ECG and the temperature of the ECG casing.

The following diagram illustrates these temperatures:

Ambient temperature of luminaire

Temperature of ECG casing (t

Ambient temperature of ECG (t

)

Exception:

For system wattages of less then 25 W, there are simpliﬁ ed evaluation criteria for harmonic content, so that in such cases a power factor of λ ~ 0.6, for example, may be permissible.

All POWERTRONIC

devices have been tested in relation to mains current harmonics content in accordance with EN61000-3-2 by VDE and carry the VDE EMC symbol:

Figure 21: Schematic diagram of a luminaire's structure

The observations of temperature must be made separately for the two system components (ECG and lamp). For the lamp there are legal provisions that restrict the temperature range and the boundary temperatures to be respected for safety reasons.

For the ECG ﬁ xed restrictions must be deﬁ ned for reasons of operational safety. Starting from the separate observation methods, there are outside inﬂ uences on luminaire installation which play a substantial role in inﬂ uencing the ECG, lamp and luminaire, as well as the choice of installation position.

Complying with the required restrictions and thus en suring operational safety is the responsibility of the manufacturer of the luminaire.

THE PRODUCT IN OPERATION

2.3.6.1. Device temperature tc

According to EN 60598-1 t

(temperature casing) is the

highest permissible temperature that may occur during normal operation under the nominal voltage (or at the maximum value of a rated voltage range) on a particular marked point of the ECG (the t

test point). It is thus

a safety-relevant value.

In practice, the temperature measured at the t

test point

of the ECG will depend on a variety of factors:

• The ambient temperature of luminaire

• Losses and the resulting self-heating of the ECG

• Luminaire design and the thermal coupling of the ECG

tothe luminaire

In order to determine the life expectancy of an ECG, the temperature of the ECG at the t

measuring point is com-

pared against the values that appear on the datasheet. In order to reach the life expectancy that is reported in thedatasheet, the t

should never be exceeded.

It is possible for each ECG manufacturer to position the t test point where he or she likes on the ECG. It may be placed at a particularly hot point or at a cooler point, and thus has a direct inﬂ uence on the real temperature measured for the device.

For OSRAM POWERTRONIC

ECGs the tc point is always positioned so that there is a good correlation between the temperature measured at the t

point and the real tempe-

ratures of the components decisive for the life expectancy of the ECG.

It is therefore possible to compare ECGs using the t perature, even where there is no other means of comparing them directly.

In practice the method used for the thermal design of luminaires and for predicting the service life of an ECG inside a luminaire is measuring the t

temperature. However,

in this context the details on expected service life must always be decided on the basis of the t

temperature for

each ECG separately.

Where ECG ambient temperatures (t

) are too low, then

theECG is not capable of ensuring reliable lamp ignition. Inaddition to this, at excessively low temperatures the properties of particular parts may change to such an extent that it leads to the failure of the ECG.

The ambient temperature should never fall below the minimum t

Where ECG ambient temperatures (t service life of the ECG may be foreshortened or the ECG

marked on the ECG.

) are too high the

may be destroyed. High ECG failure rates may occur.

Typical values for the storage of electronic control gear are the following:

Storage temperature: -40 °C to max. +80 °C Air humidity: 5 % to max. 85 %, uncondensed

It should be noted that:

Before these devices are put into service they must be re stored to the speciﬁ ed boundary temperatures for t

tem-

It should be pointed out that the absolute value of the

value represents no indication of quality, as it is me-

rely an individually placed test point used as described above for the measurement of the t

2.3.6.2. Ambient temperature t

According to EN 60598-1 t

(a=ambient) is the highest val-

of ECG

value.

ue of continuous temperature at which the luminaire (or ECG) may be operated appropriately. That means that this temperature may not exceed the t

temperature described

in section 2.3.6.1.

In the case of OSRAM POWERTRONIC ﬁ ed maximum value for t

. This relationship applies to a reference measuring

for t

has a correlation with the value

ECGs, the speci-

system in accordance with EN 61347-1 Annex D. In it the ECG is operated without any thermal connection to the luminaire.

As the ECG ambient temperature t

is determined

under the reference conditions for all ECGs, it is also suitable for making a direct comparison of the thermal properties of different ECGs.

The values for t

temperatures for each device can be ob-

tained from the technical datasheet of the speciﬁ c device.

2.3.6.3. ECG self-heating

POWERTRONIC

ECGs have an efﬁ ciency of 90 to 92 %. The remaining wattage is lost energy which causes the self-heating of the devices. Typical values for the increase in temperature of ECG casings as compared to ambient temperature are between 10 and 30 °C. This allows for a very wide range of ambient temperatures within the relevant limits, which will be quite sufﬁ cient for the most common areas of application. In cases where this is not true, the thermal properties of the luminaire need to be improved by making changes to the luminaire or to the installation position.

THE PRODUCT IN OPERATION

2.3.6.4. Practical assessment of the service life and thermal properties of an ECG

There are two ways of clarifying the life expectancy of an ECG.

1) Without any temperature measurement Comparing the t

values of the ECG with the ta tempera-

ture data shown on its technical datasheet can give an indication of the ECG life expectancy

2) With temperature measurement in a luminaire Set an ambient temperature for the luminaire (e.g. + 25 °C) → Measure the temperature at the t

test point of the ECG

to be compared and conclude the life expectancy of the ECG using the data sheet applicable to it.

→ If you only compare nominal or catalog values, then the

data on the t those on t

→ However, real measurements of the t

temperature should be preferred over

temperature.

temperature of

the ECG within a luminaire (not burning independently) and obtaining the ECG life expectancy via the indications in its data sheet, is a substantially more meaningful and realistic approach.

→ The contact of the ECG with the luminaire and the

associated improvement in heat dissipation will have a decisive inﬂ uence on its real life expectancy.

Real life measurement of the t

temperature and compa-

rison with the data speciﬁ ed on ECG life expectancy as afunction of t

temperature is the only reliable way of

ob taining the life expectancy of an ECG.

Illustrative example of such a calculation:

ECG 1:

Nominal values: t

= 80 °C

at t

→ With an ECG ambient temperature of 55 °C the max. t

= 80 °C, ta = +55 °C, 40,000 h service life

is reached, and thus a life expectancy of 40,000 h can be deduced.

ECG 2:

Nominal values: t

life = 70 °C

at t

→ With an ECG ambient temperature of 55 °C the max. t

temperature is reached; however, the t

= 80 °C, ta = +55 °C, 40,000 h service life

life has been

exceeded by 10 °C, which corresponds to a service life of approx. 20,000 h.

→ With an ECG ambient temperature of

55 °C - 10 °C = 45 °C a t 80 °C - 10 °C = 70 °C is obtained (corresponding to t

temperature of

life), leading to a service life of 40,000 h being obtained.

Conclusion:

In spite of having the same nominal and maximum t

and ta

temperatures, ECG 1 reaches a service life of 40,000 h at its max. permitted ECG ambient temperature t

In contrast, ECG 2 is only given a service life of half that duration; 20,000 h. In order to reach the same service life of 40,000 h, ECG 2 must operate at temperature t

life = 70 °C.

In this case it should be veriﬁ ed whether the ambient temperature would have to be reduced by 10 °C.

CAUTION:

A simple comparison of the absolute nominal values for

temperatures of ECGs produced by different manu-

the t

facturers does not have any meaning in relation to their properties or life expectancy, as the point at which the t measurement is made can be chosen freely by the manufacturer.

THE PRODUCT IN OPERATION

2.3.6.5. Effect of temperature on service life

The service life of an ECG is governed by the failure rate of the electronic parts used within it. The failure rates of these parts depend in turn on the particular properties of their components and the thermal and electrical loads that they are subjected to.

Extreme overheating can destroy components very quickly. Long-lasting high temperatures can also lead to premature failure. In some areas there may be an almost exponential relationship between the failure rate of an elec tronic component and the thermal load it is subjected to.

Due to this exponential relationship, exceeding the permissible t

temperature can drastically reduce the service

life of an ECG. Conversely, where this temperature limit isnot reached, the service life of the device increases disproportionately. The following graphics show the life expectancy of the various types of ECGs at a variety of t

temperatures:

PTi devices

= 40 °C/Tc = 70 °C

105

100

Operational devices ready to use (%)

0 20000 6000040000 80000 100000

t (h)

Figure 22: Life expectancy of PTi devices

Ta = 45 °C/Tc = 75 °C Ta = 50 °C/Tc = 80 °C

Ta = 55 °C/Tc = 85 °C

100000

PTo 70 3DIM

100

= 40 °C/Tc = 60 °C

Operational devices ready to use (%)

Ta = 45 °C/Tc = 65 °C

Ta = 50 °C/Tc = 70 °C

Ta = 55 °C/Tc = 75 °C

PTo 150 3DIM

100

= 40 °C/Tc = 70 °C

Operational devices ready to use (%)

Figure 24: Life expectancy of PTo 150/220-240 3DIM

= 45 °C/Tc = 75 °C

Ta = 50 °C/Tc = 80 °C

= 55 °C/Tc = 85 °C

0 20000 60000 10000040000 80000 120000

t (h)

Note:

As a rule of thumb, one may expect a doubling of service life of POWERTRONIC term reduction in the t

ECG temperature exceeds the t POWERTRONIC

devices where there is a long-

temperature of 10 °C. When the

max limit, then the

protects itself through power

re duction or shutdown (see also 2.3.7.1).

At OSRAM the t

temperature has a direct relationship with

the service life of the ECG. In the case of the PT-FIT ECG the maximum permissible temperature at the t

meter

point correlates to a life expectation of 30,000 h.

temperature is thus an essential limit, for one thing

The t

because of its importance for safety approval of luminaires in accordance with EN 60598-1 and, for another, because of its inﬂ uence on the ECG's expected service life given by the manufacturer due to the thermal load to which the components are subjected.

2.3.6.6. Failure rate

The failure rate of electronic components depends not only on the component speciﬁ cation and quality, but also strongly on the operating temperature. POWERTRONIC

devices are designed so that at the maximum permissible device temperature (t

max.) a failure rate of fewer than

2.5 ‰ per 1000 hours of operation can be expected. Given a service life of up to 60,000 hours (depending on ECG type), this corresponds to a failure rate for devices of less than 10 %. You can get more information on the failure rate in the technical datasheets.

0 20000 60000 10000040000 80000 120000

t (h)

Figure 23: Life expectancy of PTo 70/220-240 3DIM

THE PRODUCT IN OPERATION

2.3.7. General hints on installation in relation to temperature

It is essential to ensure that lamp and ECG do not heat up each other in the luminaire and that the ECG power loss can be safely dissipated even at the maximum expected ambient temperatures and/or supply voltage.

The temperature at the t

test point of the ECG may not be

exceeded even at the maximum expected ambient temperature and/or supply voltage. When measuring temperatures under "normal" operating conditions at the t

test point

a temperature should be obtained that is at least 5 to 10 °C below the maximum value indicated, in order to be sure of enough safety buffer for extreme situations.

To achieve an optimal temperature situation it may be necessary to decouple the system (e.g. putting the lamp in the luminaire head and the ECG in the base or light support) as the lamp and ECG will always warm each other upif positioned too close together, leading to excessive temperatures in the ECG. Such a separation of the parts of the system must respect the maximum permissible cable lengths between ECG and lamp(s).

→ See also wiring notes (Section 2.2.4) → See also the notes on luminaire structure and thermal

coupling (Sections 2.4 and 2.4.1)

2.3.7.1. Power reduction control due to overtemperature

It may occur that, due to suboptimal luminaire construction or by external heat sources (e.g. direct sunlight), an ECG may operate at a too high temperature; i.e. at a temperature outside the speciﬁ ed range. In order to protect the device from damage, the POWERTRONIC

will automatically reduce the output wattage. This reduction has the same effect as relieving the thermal load of the device and should protect it from irreversible damage. The reduction is limited to a maximum of 40 % of the nominal wattage. Once the device is back within the speciﬁ ed temperature range the wattage is reset. Users will notice any such power reduction control through a reduction in the luminous ﬂ ux of the affected lamps. If this is not sufﬁ cient the ECG will shut down to protect itself.

Power reduction control due to overtemperature is the "last exit" before the shutdown or destruction of the device. For this reason when designing luminaires, one should be careful that there are enough thermal reserves for the ECG at normal ambient temperatures and that the device is not already operating close to the limits.

2.3.7.2. ECG temperature measurement in the luminaire

According to EN 60598-1 there are precisely deﬁ ned test and measurement preconditions both for surface-mounted luminaires (ﬁ xed: e.g. downlights, and portable ones: e.g. free-standing luminaires) and for recessed luminaires.

The relevant temperatures of the ECG (at the t

test point)

can be best determined using stick-on thermocouples or using a suitable measurement device. You must make sure that the adhesive/glue is thermally neutral.

For ECG measurement it is generally sufﬁ cient to equip the casing cover with a thermocouple. The temperature values should only be determined when the steady state temperature of the system has been reached; i.e. when no signiﬁ cant change in temperature occurs over a longer period.

In accordance with the standards, this measurement should be done at the highest value of the rated voltage range. Itmakes sense, however, to get the measurements at the most unfavorable voltage in the rated voltage range, which is generally the lower limit of the range, since this voltage will require the highest current and thus the heaviest possible thermal load.

When assessing the thermal properties of the luminaire it is recommended to use the following procedure for the measuring system speciﬁ ed in EN 60598-1:

1. Thermal situation in the luminaire without any heating by the control gear. Luminaire in measuring system according to EN60598-1 in nominal mounting position equipped with lamp connected to ECG and thermal elements. How ever, the lamp is not operated by the built-in ECG, but by an externally wired control gear. In this way it is possible to determine only the heat generated by the lamp on the whole system and to optimize the thermal "coupling" to the environment.

2. Thermal situation in the luminaire including warming by the control gear. Arrangement as described in point 1, but with the lamp being supplied by the built-in control gear. Taking the previously obtained values into account the additional heating generated by the ECG can now be determined.

Permanent power reduction with negative effect on light quality, on efﬁ ciency and possibly even on the service life of the lamp, as well as frequent shutdown or premature aging and failure of the ECG will be logical consequences in such cases.

THE PRODUCT IN OPERATION

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

The ability of electronic control gears to withstand on/off switching is always determined in the form of the number of possible lamp starts per day. By multiplying this number with the expected service life of the gear, the total number of switchings for professional electronic control gear can be calculated.

For HID-ECGs, however, there are a number of special factors:

• High-pressure discharge lamps, due to the physics of their lamp technology are not designed for frequent switching, since, after being switched off a cooling time of roughly between 3 and 15 minutes is necessary be fore switching on again.

• In typical HID applications, therefore, there is only a small number of switches per day.

• Due to the ignition time limit in the ECG, after a particular number and duration of unsuccessful attempts at starting up the lamp, the ECG is shut down.

Switching rhythm tests have shown that POWERTRONIC

ECGs can execute 40,000 lamp starts, which corresponds to one lamp start per hour over a service life of 40,000hours.

2.3.9. Short-circuit strength

With POWERTRONIC

ECGs, the secondary outputs are short-circuit-proof for approx. 5 minutes. However, any short circuit between a lamp connection and the casing/ protective earth should be prevented at all costs, since such an accidental fault to ground will lead to the certain destruction of the ECG.

2.3.10. Switch-off criteria and mechanisms

One of the decisive advantages of lamp operation using an ECG over a CCG is the active and intelligent protection mechanisms provided by the ECG in order to ensure safe and reliable lamp operation. Below we list the most important causes of failure of high-pressure discharge lamps along with the corresponding shutdown mechanisms provided by the ECG.

2.3.10.1. Monitoring lamp voltage

One decisive parameter for ensuring safe and reliable operation of your lamp is its lamp operating voltage. POWERTRONIC

ECGs therefore carry out permanent monitoring of the lamp's operating voltage. If the lamp voltage exceeds or falls below the limits deﬁ ned for it, then the device switches off, as proper operation of the lamp can no longer be guaranteed and there is a strong probability that the lamp may be running outside its re quired speciﬁ cations.

2.3.10.2. Ignition time limitation

The EN 61347-2-12 safety standard requires that ECGs for high-pressure discharge lamps with ignition voltages of above 5 kV provide a deﬁ ned shutdown of ignition voltage after a particular length of time. POWERTRONIC

ECGs – despite having ignition voltages of less than 5 kV – are ﬁ tted as standard with an ignition time limit. That means that the ECG will shut down after a deﬁ ned time period without successful ignition of the lamp. In order to allow a reignition of the lamp with ECG after a cooling period, the shutdown of the ECG happens after 20minutes. It will once more become possible to ignite the lamp after a short mains interruption (t > 0.5 seconds). According to the above-mentioned standard, an independent autostart function by the ECG after a deﬁ ned time period (e.g. 3 hours) is not permitted.

2.3.11. Lamp shutdown at end of life

The end of the service life of a high-pressure discharge lamp may occur for a number of reasons.

Possible reasons for this might be:

• Leaky arc tube or outer bulb

• Increase of the re-ignition peak

• Breakage of the leads or electrodes in the arc tube

• Oxidation of the base contacts due to arcing in the socket

• Explosion of the lamp (HCI and HQI lamps only)

POWERTRONIC

ECGs generally operate metal halide lamps and high-pressure sodium vapor lamps safely and reliably. Of particular interest in this regard is their ability to recognize and control End of Life effects (EoL effects) of the lamps.

The intelligent ECGs are capable of detecting a variety of EoL modes in the lamps and to shut them down accordingly.

The following operating situations and discharges in the outer bulb are detected by PTi and PTo and shut down:

• Glow discharge

• Arc discharge

• Incandescent mode

Details on the above mentioned EoL cases can be found in the application guide: "Metal halide lamps"– hints on application and use"

THE PRODUCT IN OPERATION

1) Shutdown mechanism – increase in the re-ignition peak

In conventional operation the re-ignition peak is a peak in the lamp's operating voltage, after current and voltage pass through zero. With sinusoidal lamp current, the current decreases little by little, before reaching zero. As a result of the continuously decreasing current the lamp plasma cools down. This reduces further its conductivity until the supply voltage is no longer capable of re-igniting the plasma and the lamp ﬁ nally goes out.

One of the main advantages of operation using POWERTRONIC

ECGs lies in the reduced occurrence of re-ignition peaks. Since the zero crossing of the current is very steep in these devices, the times in which little or no current ﬂ ows are very short, and the plasma has less chance of cooling down.

Finally, a high-pressure discharge lamp using an ECG can be operated for longer. The smaller re-ignition peaks are to a large extent responsible for the longer service life through ECG operation as compared to conventional choke operation.

2) Shutdown mechanism – rectifying effect

Uneven heated electrodes, the malfunction of an electrode or discharge in the outer bulb are all possible causes of asymmetric operating mode (rectifying operation) of highpressure discharge lamps. The rectifying effect causes a high DC voltage component. As a result, a conventional choke will go into saturation, which will drastically reduce choke impedance. In extreme cases the lamp current will be restricted only by the ohmic resistance of the choke. This may result in the choke and ignitor overheating.

With POWERTRONIC constantly monitored and adjusted by a microcontroller. POWERTRONIC

ECGs, current and voltage are

ECGs shut down before rectifying effects can lead to damage of the ECG thus allowing them to offer a clear plus in terms of safety over conventional control gears.

2.3.12. Noise levels

POWERTRONIC

ECGs are so quiet in operation that even in a quiet environment they can hardly be detected. Theirlimit is generally < 30 dB(A). In comparison to this, here are guideline values for acceptable room noise intensity:

• For an ofﬁ ce: 35 dB(A)

• In a shop: 35 dB(A)

Factors that inﬂ uence the noise intensity levels are the noise emitted by each separate electronic control gear, the acoustic properties of the luminaires in which they are ﬁ tted, the way the ECGs are mechanically attached into the luminaires, the sound absorption properties of the room, as characterized by volume and reverberation time, as well as the total number of electronic control gear units.

Tip:

In order to develop a luminaire that makes as little noise as possible, a sufﬁ cient decoupling of the ECG and the luminaire body is essential; i.e. the ECG should not have full contact with the luminaire chassis, but it should be only connected at points or mounted using the rubber absorbers that are also used for CCGs.

This method of mounting may under some circumstances lead to thermal problems (the maximum permissible temperature at the t

point may be exceeded due to the bad

thermal coupling), as the heat may be best dissipated with full-surface mounting. Solving this problem with an appropriate casing construction and/or method of mounting the luminaire (with forced ventilation or cooling, or enhanced convection) has the advantage of reducing the operating sound and therefore it should be taken into consideration.

Tests have shown that noise levels depend on the operating temperature of the electronic control gear. This factor has a particular role if the ECG has been mounted according to the above-mentioned recommendations. In extreme cases it may not be possible to do without an additional heat sink.

In addition, noise levels rise disproportionately with increasing temperatures in the ECG. For this reason it is recommended to run the ECG at a temperature lower than the maximum permissible operating temperature. In practice, this means that the lower the temperature at the t

test

point, the lower the noise level. The ideal solution would be to use the double strategy of mounting the ECG in an acoustically decoupled manner and running it at a lower temperature.

2.3.13. Dimming

High-pressure discharge lamp systems based on highpressure sodium vapor or metal halide lamps can generally be operated at reduced power. However, it should bekept in mind that dimmed operation will bring with it losses in light quality and efﬁ ciency (lm/W). For this reason dimming of HID lamps can only be recommended for outdoor lighting applications. Therefore, POWERTRONIC

PTi

and PT-FIT devices do not provide any dimming function.

In the interests of energy savings and CO

reduction, there

is now a demand for dimming capacity of lighting installations used for outdoor applications. The loss of light quality can be tolerated late at night, as the number of motorists reduces rapidly during the course of the night. For this reason, OSRAM has developed the ideal ECG solution with the PTo family, which has been ﬁ tted out with the 3DIM feature. 3DIM stands for DALI

, StepDIM and AstroDIM.

THE PRODUCT IN OPERATION

The user can choose here between three different dimming modes:

Lumen

Time

Figure 25: DALI® – Digital Addressable Lighting Interface

DALI

is a communication standard that is widely used by

luminaire manufacturers. DALI

works bidirectionally as part of a tele-management system, and offers the user a number of control and settings options for each light source.

Where no control line exists in the system the user can use the AstroDIM function. Using it one can dim the luminaire without an external control by deﬁ ning a time window (e.g. within six hours) within which the lamp is dimmed from 100 to 60 % and is then turned back up again.

All three dimming settings can be adjusted using a software tool and can be changed back again at any time. For this purpose OSRAM provides the DALI magic interface standard and the 3DIM Tool software package as a download.

More detailed information on the 3DIM topic can be found in www.osram.com/3dim.

Lumen

Time

Figure 26: StepDIM

StepDIM is the possibility to regulate a luminaire in a single step via a control cable to a particular dimming factor (e.g. from 100 to 60 %).

Lumen

Time

Figure 27: AstroDIM

THE PRODUCT IN OPERATION

Dimming means reducing wattage to save energy. The following values emerge per DIM level, lamp type andwattage for each system.

Light and wattage details for a PTo 50 3DIM system

PTo 50 3DIM HCI-TT 50W WDL NAV-T 50W Super

DIM-Level [%]

100 50.5 56.4 4960 98.1 87.9 3041 79 4005 79.3 71.0

90 45.7 51.2 4375 95.7 85.5 3183 75 3380 73.9 66.0

80 40.6 45.6 3725 91.8 81.7 3389 71 2715 66.8 59.5

75 37.9 42.7 3375 89.1 79.0 3521 69 2380 62.7 55.7

70 36.0 40.6 3115 86.6 76.7 3634 67 2140 59.4 52.7

60 33.6 38.1 Not released, dimming to 60 % 1890 56.3 49.6

PL [W]

PS [W]

PHI [lm]

ETA [lm/W]

ETA sys [lm/W]

CT [K]

Ra PHI

[lm]

ETA [lm/W]

ETA sys [lm/W]

Light and wattage details for a PTo 70 3DIM system

PTo 70 3DIM HCI-TT 70W WDL NAV-T 70W Super

DIM-Level [%]

100 73.3 80.9 7150 97.5 88.4 3003 89 6810 92.9 84.2

90 64.5 71.4 6280 97.4 88.0 3056 84 5675 88.0 79.5

PL [W]

PS [W]

PHI [lm]

ETA [lm/W]

ETA sys [lm/W]

CT [K]

Ra PHI

[lm]

ETA [lm/W]

ETA sys [lm/W]

80 56.6 62.8 5435 96.1 86.5 3141 80 4595 81.2 73.1

75 51.8 57.8 4890 94.4 84.7 3225 78 3940 76.0 68.2

70 47.8 53.4 4430 92.7 82.9 3322 75 3400 71.2 63.7

60 46.1 51.8 4175 90.5 80.6 3439 73 3150 68.3 60.8

THE PRODUCT IN OPERATION

Light and wattage details for a PTo 100 3DIM system

PTo 100 3DIM HCI-TT 100W WDL NAV-T 100W Super

DIM-Level [%]

100 98.0 106.1 10695 109.1 100.8 3009 86 10670 108.8 100.5

90 85.0 92.3 9215 108.4 99.9 3057 83 9420 110.8 102

80 74.2 80.9 7870 106.1 97.3 3151 79 8020 108 99.1

75 67.0 73.4 6930 103.5 94.3 3255 76 6550 97.7 89.2

70 62.7 69.1 6345 101.1 91.8 3338 74 5085 81.1 73.6

60 59.3 65.7 5790 97.6 88.1 3464 72 4300 72.5 65.4

PL [W]

PS [W]

PHI [lm]

ETA [lm/W]

ETA sys [lm/W]

CT [K]

Ra PHI

[lm]

ETA [lm/W]

ETA sys [lm/W]

Light and wattage details for a PTo 150 3DIM system

PTo 150 3DIM HCI-TT 150W WDL NAV-T 150W Super

DIM-Level [%]

100 148.5 161.9 16400 110.4 101.3 3009 88 17820 120.0 110.1

90 136 148 15010 110.4 101.4 3069 84 16010 117.8 108.2

PL [W]

PS [W]

PHI [lm]

ETA [lm/W]

ETA sys [lm/W]

CT [K]

Ra PHI

[lm]

ETA [lm/W]

ETA sys [lm/W]

80 121 132 13230 109.3 100.2 3222 79 13720 113.4 104.0

75 104.0 114 11050 106.2 97.0 3343 76 11020 105.9 96.7

70 92 101 9445 102.6 93.5 3502 73 9095 98.8 90.0

60 84 91.7 8230 97.9 89.7 3661 70 7800 92.9 85.1

Clariﬁ cations:

Please note: The values shown should be considered asexamples, as lamps and control gear are subject to

PL Lamp wattage

tolerances due to a number of factors. The measured values indicated were obtained photometrically in a two-

PS System wattage (lamp + control gear)

PHI Luminous ﬂ ux

ETA Lamp luminous efﬁ cacy

ETA sys Luminous efﬁ cacy of lamp + control gear

CT Color temperature

Ra Color rendering

meter integrating sphere at a room temperature of25 °C.

THE PRODUCT IN OPERATION

2.4. Hints on luminaire design

The general recommendations on luminaire design by IEC and the national authorities (VDE, KEMA, ANSI, etc.) should be followed.

In addition, it should be noted that POWERTRONIC

systems may be subject to ignition voltages of up to 4.5 kV. Components (sockets, cabling, etc.) and materials should be selected in accordance with these requirements. Data on the lamps to be used can be found in the relevant IEC standards 61167 (for metal halide lamps) and 60622 (for high-pressure sodium vapor lamps). In addition to these, the international standard for luminaires IEC 60598 is also relevant.

Notes on the wiring can be found in section "2.2.4. Wiring" while notes on conformity with EMC guidelines in section "2.2.4.4. Cable layout".

2.4.1. Thermal coupling

POWERTRONIC

ECGs have an efﬁ ciency of 90 to 92 %. The remaining wattage is lost energy which causes the self-heating of the devices. Due to their excellent efﬁ ciency, ECGs are subject to relatively little self-heating. However, to achieve the maximum possible device service life and the minimum failure rate, this heat must be conducted away from the device as efﬁ ciently as possible. Especially for the integration in luminaires the following should be kept in mind:

• Use appropriate measures to achieve good heat transfer

between the POWERTRONIC

device and the luminaire

casing.

− Direct, wide-surface contact between the ECG and the luminaire casing.

− Make luminaires out of highly conductive materials, such as metals.

• Prevent air-ﬁ lled gaps between the ECG and the luminaire casing – Air has an insulation effect

− Do not mount the ECG on internal housing beams

− Do not use any spacers between the ECG and the luminaire casing in order to fasten the ECG into the luminaire.

− Place any mounting or holding plates in such a way as to ensure wide-surface contact between the ECG and the luminaire casing.

• Do not place any insulation material between the ECG and the luminaire casing

− Do not use double-sided tape to secure the ECG

− Do not place any materials with low heat conductivity between ECG and luminaire

• In order to achieve particularly good heat conductivity at critical positions thermal pads can be placed between the ECG and the luminaire casing.

• Ensure a clearance between the ECG and the lamp (ideally ≥30 cm); provide a separate chamber for the ECG; otherwise use cooling plates or heat sinks in orderto keep heat radiation away from the device.

In all cases it will be necessary to measure temperature t at the test point in order to ensure that t

max.is not ex-

ceeded.

2.4.2. Ventilation slits, cooling ﬁ ns

Ventilation slits in the luminaire ensure direct ventilation of the interior of the luminaire and thus allow the ECG to be cooled directly. The ventilation slits (for air in and out) should have a minimum width of 4–5 mm and should be arranged so that there is an air current ﬂ owing over the ECG no mater where the luminaire is positioned. Cooling ﬁ ns on the outside surface of the luminaire increase its surface and thus contribute to improved thermal radiation properties for the luminaire.

2.4.3. Materials that may be used in luminaire structures

Depending on design and intended applications, both plastics and metals can be used in building luminaires for HID systems. Each material has its own individual properties. The main consideration to be kept in mind, however, is that the material being used satisﬁ es the thermal requirements demanded by the heat radiated from the light source. In addition, these materials need to have the appropriate resistance to UV light.

More information on this topic can be found in the application guide: "Metal halide lamps – hints on application and use"

From the ECG point of view, the best possible heat transfer should be the target (see also section "2.4.1 Thermal Coupling")

2.4.4. Installation-friendly ECG

Depending on the intended application and the mounting conditions in the luminaire, a built-in ECG or one with a cable clamp can be used. Both the built-in devices (PTi S or B, PT-FIT S or B and PTo) and the devices with cable clamp (PTi I or SNAP and PT-FIT I) are particularly easy to mount.

S version for installation in luminaires

Figure 28: PTi 70/220-240 S

• Mounting the device using a grommet on its bottom or side

• Plug terminals for fast connection and release of wires without tools

• Stable and robust metal casing

THE PRODUCT IN OPERATION

B version for installation in luminaires: PTi I version for independent mounting with cable clamps:

Figure 29: PT-FIT 70/220-240 B Figure 31: PTi 70/220-240 I

• Mounting the device using grommets on the bottom

• Plug terminals for fast connection and release of wires without the need for tools

• The luminaire casing must provide protection in order to satisfy the EN 60598-1 and EN 61347-2-12 safety standards

PTo for installation in luminaires:

Figure 30: PTo 100/220-240 3DIM

• Mounting the device using grommets on the bottom

• Plug terminals for fast connection and release of wires without the need for tools

• Robust plastic casing

• For protection against moisture and damp, the inside of the casing (board) is potted

• Large terminal compartment gives good access to terminals

• A generously proportioned terminal compartment allows for a ﬂ oating terminal for mains looping

• The LUM PE connection allows safe and lasting direct earthing of the luminaire via the ECG's protective earth

• Cable clamp suitable for a variety of cable types and diameters between 7 and 11 mm

• PTi variants 20, 35, 50 and 70 offer mains looping

• Separate cable clamps for separate access to primary and secondary side

• Only a single screw per cable clamp cap for fast and yet secure cable ﬁ xation

PTi SNAP version for independent mounting with integrated connectors

Figure 32: PTi 70/220-240 SNAP

• With integrated universal ST18 plug connection on the lamp side and GST18 plug connection on the mains side for fast, error-free installation

• With cable clamp integrated into casing

THE PRODUCT IN OPERATION

2.4.5. Installation space for independent devices

POWERTRONIC

PTi/PT-FIT I devices with integrated cable clamp are ideal for use in suspended ceilings. In such applications the diameter of the ceiling cut-out depends on the installation height available.

The following table gives an overview of the ceiling cut-out required as a function of the installation depth of the various devices with cable clamp.

Indicative details for devices in suspended ceilings

PTi 20 I PTi 35 to 70 I

PT-FIT 35 to 70 I PTi 35 to 70 SNAP

∅ (mm) h (mm)

95 65 80 x 140

104 55 70 110 105

125 40 55 75 70

145 35 45 65 60

PTi 2x35 I PTi 2x70 I

PTi 100 I PTi 150 I

OSRAM provides the following Plug-&-Play solutions:

• PTi SNAP (with integrated connectors)

• PTi I/P and PT-FIT I/P (prefabricated lamp cable with plug)

• PTi I/2P and PT-FIT I/2P (prefabricated lamp and mains cable with plugs)

To ensure that the installation of the cable plug-in system is quick, reliable and, most importantly, safe, the following tests are carried out by OSRAM as part of prefabrication:

• High-voltage test

• Insulation test

• Function test

2.4.7. Passing network cabling through via "ﬂ oating"

terminal

Due to their generously sized terminal compartment, independent POWERTRONIC

ECGs with cable clamp allow the use of a terminal (e.g. a Wago terminal) to pass the mains cable from one device to the next. In order to use this option it should be kept in mind that the cable temperatures must not exceed the maximum permissible levels in the ECG.

2.4.8. Lamp sockets that may be used

In principle, all sockets that conform to the requirements for high-voltage can be used to operate the appropriate lamps with a POWERTRONIC

ECG. Generally, an ignition voltage of up to 4.5 kV can occur. Further details can be found on the stamp of the relevant ECG or in its technical information sheet.

Figure 33: Schematic diagram of the installation space for independent devices

To ensure optimal thermal isolation, independent devices should be positioned at a sufﬁ cient distance (> 30 cm) from the luminaire.

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

Especially in the project sector, the use of plug-in cable systems is always preferred. Such Plug-&-Play solutions offer the following beneﬁ ts:

• Quick and easy connection of the ECG with the luminaire and of the mains to the ECG

• A coded plug-in system reduces polarity errors in the installation

• The wiring for the ECG has been factory tested

When connecting the socket (or the luminaire) to the ECG it is essential to ensure that Lamp High and Lamp Low, i.e. the ignition cables with high and low potential respectively, are correctly connected.

The following list indicates the most commonly used sockets for metal halide lamps suitable to be operated by the ECG:

Examples of socket types

Socket type Lamp type Lamp designation

G12/G22 Pin base lamp HCI-T, HQI-T

G8.5 Pin base lamp HCI-TC

Rx7s/Fc2 2-sided socketed lamp HCI-TS, HQI-TS

E26/E27/E40 (suitable for high voltage)

GU 6.5, GU 8.5 Bayonet base HCI-TF, HCI-TX/P

GX 8.5, GX 10 Twist and Lock HCI-R111

Screw base HCI-PAR, HCI-TT,

HCI-ET, HCI-E/P

The polarity must be kept in mind especially for E26/E27 and E40 screw bases.

THE PRODUCT IN OPERATION

L N

GND

L N

For all versions it is important to keep in mind the typical conditions required for discharge lamps; namely high ignition voltage and temperatures. The selection and technically correct integration of lamp sockets in accordance with the applicable standards (e.g. IEC 60598/VDE 0711, IEC 60335/VDE 0700) is the responsibility of the user. Sockets consist of several components, each of which have their own functional limits. Failure to remain within these limits will cause premature failure of the socket.

More information on the integration and use of lamp sockets can be found in the OSRAM application guide: "Metal halide lamps" – hints on application and use"

L N

GND

When changing the system (from HQL to NAV or HCI lamps), the socket must be tested and/or replaced.

2.4.9. Protection against electrostatic build-up in

outdoor luminaires

Electrostatic charge in metal parts of outdoor luminaires may in some circumstances cause failure or damage to the ECG. Such metal parts are charged by clouds or lightning storms and may reach voltages of up to 50 kV. In order to prevent their discharge onto the ECG, the following aspects in the luminaire design should be considered, to ensure a problem-free operation of the ECG:

1. Connection or wiring between the metal part of the

luminaire and the "Equipotential" terminal

of the ECG

2. The distance between this metal part and the ECG

should be at least 8 mm

3. The lamp cables should have double insulation

These measures should ensure that high voltages can be limited to 6 to 8 kV. The PTo can generally withstand such voltages.

When installing the luminaire on masts, depending on the mast being used, further preventive measures may be needed, so that no electrostatic discharges can reach the luminaire from the ground via the mast.

Figure 34: Safe connection with lightning conductor outside – Class I luminaire

L N

Figure 35: Safe connection with lightning conductor outside – Class II plastic luminaire

L N

Figure 36: Safe connection with lightning conductor outside – Class II metal luminaire

THE PRODUCT IN OPERATION

2.4.10. Protection against moisture in outdoor luminaires

PTo ECGs have been developed for outdoor luminaires with a higher IP Class (IP Class 54 or higher spec luminaires are suitable). The potted construction leaves them better protected in the face of climatic effects (moisture, condensation, etc.). For older lighting installations (luminaires) or due to increased material fatigue of luminaire components (seals, covers, etc.) an installation that protects from spray water or precipitation should be preferred.

2.5. Electromagnetic compatibility

The term EMC (electromagnetic compatibility) and the stipulations relating to it stand for a whole range of different test criteria.

The most important of these criteria that play a role in the context of electronic control gears are regulated by the standards described below in relation to radio interference, harmonic content (up to the 39th harmonic) and resistance to interference.

List of the most important standards for ECGs

IEC/CISPR International Standards

Harmonics IEC 61000-3-2 EN 61000-3-2

Resistance to interference IEC 61547 EN 61547

European standard EN

2.5.1. Speciﬁ ed harmonic limits

Lighting installations are restricted in relation to mains harmonics. They are classiﬁ ed and are categorized in ClassC. Up to 25 W lighter requirements apply.

For lighting installations > 25 W the following limits are speciﬁ ed:

Speciﬁ ed harmonic limits

Harmonic number Proportion of fundamental mains current in % (50 Hz)

3 30 x power factor (λ)

510

11 < n < 39 3

All POWERTRONIC

ECGs (> 25 W) for use with HCI, HQI and NAV lamps must have a total harmonic distortion (THD) < 10 %.

Radio interference CISPR 15 EN 55015

Electromagnetic ﬁ elds IEC 62493 EN 62493

By displaying the CE marking OSRAM guarantees the conformity of POWERTRONIC

electronic control gear with the interference resistance requirements and the speciﬁ ed limits for harmonic currents and for radio interference (as well as for safety). See also section 3.2 "Quality marks".

Employing devices that do not conform to the speciﬁ ed harmonics limits may have serious consequences:

• Premature failure of capacitors

• Premature triggering of circuit breakers and other safety equipment

• Failure or functional problems with computers, drivers, lighting installations and other sensitive electric devices

• Overload of the neutral conductor (especially in the 3rd harmonic)

• Explosion of discharge lamps

2.5.2. Resistance to interference, immunity

The devices conform to the requirements of IEC 61547 on immunity. This means that they are protected against external inﬂ uences of electromagnetic ﬁ elds against static electrical discharges (ESD), against short-term (transient) surge voltage and voltage drops or failures in the mains network.

THE PRODUCT IN OPERATION

2.5.3. Radio interference

Conformity with the speciﬁ ed limits for radio interference is a precondition for granting of the VDE-EMC mark by theVDE independent testing institute based in Offenbach, Germany.

Our electronic control gear (ECGs) are tested in a test setup via a reference luminaire, as described in CISPR 30.

ECGs for independent assembly, in contrast, are tested exclusively according to CISPR 30. The levels of interference of a luminaire, however, not only depend on the ECG, but also on a number of factors:

• The arrangement of lamp and ECG components

• The structure of the luminaire

• Wiring

For this reason, conformity to the speciﬁ ed limit for a luminaire considered as a systematic whole is substantially more complex and must be tested separately for each luminaire approval (e.g. by the VDE testing institute). Themanufacturer of the luminaire is responsible for this.

2.5.3.1. Causes of radio interference

The term "radio interference" includes both the interference through the lines as well as the radiated interference from any electric device on another device on the same power network and/or in the immediate vicinity.

In order to ensure simultaneous, fault-free operation of the widest possible variety of electric devices, each of those devices must conform to particular limits and demonstrate acertain level of resistance to interference.

POWERTRONIC® ECGs are based on a high-frequency circuit topology to achieve higher energy efﬁ ciency and compact size. These high-frequency switching processes, together with non linear components (such as diodes, transistors, etc.) can create interference with the mains and lamp cables of the ECG. Both the mains and lamp cables can function as antennas in this context.

The greater part of the electromagnetic radiation is transferred onto these cables. Under unfavorable conditions the lamp cables can form a resonator in combination with the luminaire, thus leading to increased emission (λ/4, 100 MHz → l = 75 cm). The resonance cycle is inﬂ uenced by the inductivity of the cables, the capacitative coupling of cables with metallic surfaces of the luminaire and the lamp being used. Provided that as this resonance cycle cannot be controlled by structural measures it is recommended to apply ferrites to the lamp cables.

2.5.3.2. Hints on installation to prevent radio inter ference

Since the cable layout has a decisive inﬂ uence on the radiation characteristics of a luminaire, it is essential to make sure that cables are positioned carefully inside (and outside) the luminaire as described in section 2.2.4.4.

With the use of complex internal EMC ﬁ lters the interference described above is reduced to levels below those required by the relevant standards, so that the OSRAM electronic control gear themselves conform to these standards. However, installing the ECG into luminaires can signiﬁ cantly change these properties.

THE PRODUCT IN OPERATION

2.6. Errors, causes and solutions

Error Causes Solutions

Lamps obviously too bright or not bright enough Check whether a lamp with the right wattage is installed If necessary change the lamp or the ECG

The lamp ﬂ ashes on and off The lamp has reached the end of its useful life and can

The device switches off after some time in operation The ECG is being operated outside speciﬁ cations Adjust luminaire design or environment

Lamp does not ignite (for 2-lamp systems, neither of them ignites) and no visible glow can be seen shortly after switching on (the same occurs when the device is switched on even after a minute of downtime and after an internal device reset).

no longer be used in a stable state

The ECG is being operated in a hot environment and switches off in order to prevent irreversible damage

Mains voltage outside the permissible range Adjust luminaire design or environment

Lamp type not suitable for ECG (e.g. NAV with PTi) If necessary change the lamp or the ECG

• RCD or some other protective component in the system has been triggered

• Has the maximum permitted number of electronic control gears per automatic cut-out been exceeded forthe installation in the 3-phase network?

• Is it absolutely sure that the neutral conductor is correctly connected to all the ﬁ xtures and that it is making proper contact?

• Is it possible that moisture has got into the luminaire, causing a short circuit?

Failure in the mains side wiring Check whether the mains input voltage, suitable for the

The irreversible surge protection in the ECG has been triggered (the ECG is permanently damaged)

Change the lamp

Adjust luminaire design or environment. To restart, power supply must be interrupted.

Check the mains side wiring and, where applicable, the insulation consistency

speciﬁ ed area of application is actually present at the ECG. Make absolutely sure that the neutral conductor is correctly connected to all the luminaires and that it is making proper contact. Check whether all cables have the correct connection in the terminals.

Check whether the lamp is working using other lighting outlets. If this is not the case, check the mains input voltage to see whether it is within the speciﬁ ed range. If the neutral conductor is both properly connected and it is making proper contact, then both the ECG(s) and lamp(s) must be replaced.

Different lumen output levels between luminaires Lamps with different wattages/light colors have been

Problems with other electrical devices, especially with radio or TV receivers

installed

The wiring between ECG and lamp is faulty; there may bea contact problem

Has the lamp wiring been installed according to the indications on the ECG?

The ECG is operating outside the speciﬁ ed temperature range and is trying to reduce the thermal load on the lamp via power reduction control ("forced dimming")

Wiring problems See also the information in section 2.2.4.4. Cable layout

Other electrical devices or receivers have insufﬁ cient resistance to interference

The lamp type and wattage must match the type indicated on the ECG. For any particular application, the chosen light color should be uniform.

Check the wiring on the lamp side for proper contact

Where necessary wire up the lamp according to the indications on the ECG

Check whether the ECG is operating above the speciﬁ ed temperature in the affected luminaires. Make structural changes in order to lower the heat load on the device.

Increase the distance between the luminaire and the affected electrical device or receiver; where necessary contact the manufacturer of the device.

STANDARDS, QUALITY MARKS AND CE LABELING

3. Standards, quality marks and CE labeling

3.1. Standards

3.1.1. Safety EN 61347-2-12 together with EN 61347-1

"Lamp control gear – Part 2-12: Particular requirements for DC or AC supplied electronic ballasts for discharge lamps (excluding ﬂ uorescent lamps)" together with "Lamp control gear – Part 1: General and safety requirements"

The EN 61347-2-12 standard sets out particular general and safety requirements for AC and DC supplied electronic control gears. The supply covered includes AC voltages up to 1000 V at 50 or 60 Hz. The ballast type is aconverter that may contain components for ignition and stabili zation for operating a discharge lamp using DC or using a frequency different to the mains frequency.

The lamps connected to the control gear are governed by IEC 60188 (high-pressure mercury vapor lamps), IEC60192 (low-pressure sodium vapor lamps), IEC 60662 (high-pressure sodium vapor lamps), IEC 61167 (metal halide lamps) as well as other standards for general lighting purposes.

In addition, the EN 61347-2-12 also sets out the extent towhich a section of EN 61347-1 is applicable and determines the sequence in which the required tests should becarried out.

The standard does not apply to built-in ECGs. How ever, the following sections are set as a standard for independent ECGs: Construction (cable layout, connection terminals, connection points and mains connections, mechanical stability), external andinternal cabling (mains connection and other external cabling, cable strain relief mechanism), protection against electric shock, protection against dust, solid foreign objects and water, insulation resistance, electric strength, contact current and protective current, clearance and creep distances.

For independent ECG conformity to these standards is a precondition for the VDE-EMC mark and for CE conformity.

3.1.2. Electromagnetic compatibility (EMC) EN 55015

"Limits and methods of measurement of radio disturbance characteristics of electrical lighting and similar equipment"

The EN 55015 standard applies to emissions (both radiated and conducted) of high-frequency interference by, among other things, all lighting equipment with the main purpose of creating and/or distributing light for purposes of illumination, which are designed either for the low-voltage network or for battery operation, and for independent accessories for use exclusively with lighting applications.

The standard mainly sets the requirements for the following topics: Labeling (of PE/FE, terminals, wiring, ignition voltage, U-OUT), connection terminals, protective earth connections, protection against accidental contact with live parts, water resistance and insulation, electric strength, failure conditions, protection of components, ignition voltage, anomalous conditions (behavior of the ECG at the end of lamp life), design, creep and clearance distances, screws, conductive components and connections, heat and ﬁ re resistance, creep resistance, resistance to corrosion.

Conformity with the standard is a precondition of granting the VDE-EMC mark and for CE conformity.

EN 60598-1

"Luminaires – Part 1: General requirements and tests"

The EN 60598-1 standard sets the general requirements for luminaires containing electrical light sources suitable for operation at supply voltages of up to and including 1000 V. The requirements and the corresponding tests set in this standard apply to: classiﬁ cation, labeling, mechanical and electrical design.

The limits speciﬁ ed in this standard have been set, based on the probability that radio interference remains within economically acceptable limits and that, more generally, sufﬁ cient protection is ensured for radio reception and for electromagnetic compatibility. In unfavorable circumstances, additional measures may be required.

The standard includes regulations and methods of measurement of interference in the frequency range from 9 kHz to 300 MHz.

In this regard it sets the speciﬁ ed limits for interference voltage due to the cable layout in the frequency range up to 30 MHz on the mains connections and on the secondary and control terminals. In addition, for radiated interference, limits are speciﬁ ed for the magnetic component of the interference ﬁ eld strength in the frequency range of 9 kHz to 30 MHz and the electrical component of that interference ﬁ eld strength in the frequency range of 30 MHz to 300 MHz.

The measurement of interference in the frequency range of30 to 300 MHz can be carried out using the CDN procedure for interference due to cable layout.

STANDARDS, QUALITY MARKS AND CE LABELING

The limit speciﬁ ed for conducted interference for use with the CDN procedure is comparable with the limit for radiated interference and provides adequate protection to radio services using the frequency range of 30 to 300 MHz.

Conformity with the standard is a precondition of granting the VDE-EMC mark and for CE conformity.

EN 55022

"Information technology equipment – Radio disturbance characteristics – Limits and methods of measurement"

The EN 55022 standard describes the procedure for measuring the level of interference signals that may be created by information technology equipment facilities, and sets out limits for the frequency range from 9 kHz to 1 GHz.

The standard does not apply to ECGs.

EN 61547

"Equipment for general lighting purposes. EMC interference resistance requirements"

The EN 61547 standard sets requirements for the electromagnetic interference resistance of lighting equipment; it does so both for connection to the low-voltage network and for battery operation.

The regulation includes requirements for ECG immunity against the following external disturbing inﬂ uences: Static electrical discharge, high frequency and network frequency electromagnetic ﬁ elds, fast transients, current inputs, surge currents/voltages, voltage drops and interruptions, voltage ﬂ uctuations.

Conformity with the standard is a precondition of granting the VDE-EMC mark and for CE conformity.

EN 61000-3-2

"Electromagnetic compatibility (EMC) – Part 3-2: Limits – Limits for harmonic current emissions (equipment input current ≤ 16 A per phase)"

The EN 61000-3-2 standard applies to the limitation of the amount of harmonic currents that may be introduced into the public low-voltage network. It sets limits to the harmonic current component of input current that may be generated by a device equipment or facility, which is tested under speciﬁ ed conditions. Different limits and testing methods are valid for lighting installations with an effective input power up to 25 W or greater than 25 W.

Conformity with the standard is a precondition of granting the VDE-EMC mark and for CE conformity.

EN 61000-3-3

"Electromagnetic compatibility (EMC) – Part 3-3: Limits Limitation of voltage changes, voltage ﬂ uctuations and ﬂ icker in public low-voltage supply systems, for equipment with rated current up to 16 A per phase and not subject to conditional connection"

The EN 61000-3-3 standard applies to the limitation of the amount of voltage ﬂ uctuations and ﬂ icker that may be caused into the public low-voltage network. It sets out limits for changes in voltage that may be generated by devices and systems, which are tested under speciﬁ ed conditions, and gives information about calculation pro cedures.

Conformity with the standard is a precondition of granting the VDE-EMC mark and for CE conformity.

EN 62386 (for PTo devices only)

This standard describes the DALI

industry standard and sets out a protocol and a testing procedure for the control of electronic control devices with digital signals for purposes of illumination. The tests described in this draft standard are type approval tests. Requirements for the testing of individual control gears during production are not included.

An overview of the DALI

standard:

• All control gears must conform to Part 102.

• A single operating device may belong to more than one

device type (see Part 100, 200, 300).

• Speciﬁ c commands and properties are deﬁ ned and

described in the Parts numbered 2xx.

Digital Addressable Lighting Interface Standard

Part 100: General requirements

Part 101: System Part 201: Fluorescent

Part 102: Control gear

Part 103: Controllers Part 203: Discharge

Part 200: Special requirements for control gears

lamps

Part 202: Emergency lighting

lamps (HID)

Part 204: Low-voltage halogen lamps

Part 205: Incandescent bulbs

Part 206: Conversion of a digital signal to DC voltage

Part 207: LED modules

Part 208: Switching function

Part 209: Color and color temperature control

Part 300: Special requirements for controllers

Part 301: SML description

Part 302: 3-byte protocol

Part 210: Sequencer

Part 211: Optical control

STANDARDS, QUALITY MARKS AND CE LABELING

EN 62493 (for PTi I, PT-FIT I and PTi SNAP devices only)

This standard applies to the assessment of lighting equipment in relation to the exposure of persons to electromagnetic ﬁ elds. The assessment contains induced current densities from 20 kHz to 10 MHz and the speciﬁ c absorption rate (SAR) for frequencies from 100 kHz to 300 MHz inthe immediate vicinity of lighting equipment.

3.2. Quality marks

3.2.1. The VDE label

By granting the VDE label, the VDE testing and certiﬁ cation institute certiﬁ es that the relevant ECG conforms with the safety standards listed in the approval certiﬁ cate from the point of view of the EC Low Voltage Directive. Certiﬁ ed products are subject to factory inspection and manufacturing monitoring.

At the same time, the approval certiﬁ cate forms the basis of the EC Declaration of Conformity and the CE marking made by the manufacturers or their authorized persons.

The VDE label for ECGs for the operation of high-pressure discharge lamps includes conformity with the EN 61347-2-12 safety standard in conjunction with EN 61347-1.

3.2.2. The ENEC mark

The ENEC mark stands for "European Norm Electrical Certiﬁ cation" and is the agreed symbol of conformity of the European Union's inspection authorities. It symbolizes conformity with the European safety and workplace standards listed in the ENEC agreement. As is the case with the VDE label, in addition to indicating the type approval tests made on the ECG, the ENEC mark also covers the continuous monitoring of both the manufacturing process and the relevant products. The number that appears to theright of the symbol stands for the relevant certiﬁ cation authority. For example, 10 stands for the VDE test and certiﬁ cation institute in Germany.

The ENEC mark for ECGs for the operation of high-pressure discharge lamps includes conformity with the EN 61347-2-12 safety standard in conjunction with EN 61347-1.

3.2.3. The VDE-EMC mark

By granting the VDE-EMC mark, the VDE testing and certiﬁ cation institute certiﬁ es that the relevant ECG conforms with the safety standards listed in the approval certiﬁ cate from the point of view of the EC Directive on electromagnetic compatibility. At the same time, the approval certiﬁ cate forms the basis of the EC Declaration of Conformity and the CE marking made by the manufacturer or their authorized person.

The VDE-EMC mark for ECGs for the operation of highpressure discharge lamps includes conformity with the EN 55015, EN 61547, EN 61000-3-2 and EN 61000-3-3.

3.2.4. The CCC/CQC mark

The CCC symbol is a compulsory safety and quality mark for a variety of products that are sold in the Chinese market. It became applicable on 04/30/2003. In order to be granted the CCC mark, the product's conformity with Chinese standards must be certiﬁ ed by a testing laboratory approved by the CNCA (Certiﬁ cation and Accreditation Administration of the People's Republic of China). The standard also requires a plant inspection.

There is no CCC mark available for HID ECG. Apart from the compulsory certiﬁ cation, the China Quality Certiﬁ cation Centre also provides a voluntary product certiﬁ cation, the CQC mark. To obtain this mark, products are tested against standards for quality, safety, EMC, environmental friendliness or functioning.

The difference between the CCC and the CQC is that the CCC is compulsory while the CQC is voluntary. The process is identical. Since luminaires using HID lamps need CCC certiﬁ cation, it is advantageous to have the CQC mark on the HID ECG when applying for approval of the luminaire.

3.2.5. The C-tick/RCM mark

This is an approval mark of the Australian standards authorities.

3.2.6. The GOST mark

This is an approval mark of the Russian standards authorities.

STANDARDS, QUALITY MARKS AND CE LABELING

3.3. The CE marking

The CE marking for products is a symbol deﬁ ned by EU law with which a manufacturer declares his or her conformity with the relevant EC Directives. For OSRAM's POWERTRONIC

products, the relevant documents are the Low Voltage Directive 006/95/EC and the EMC Directive 2004/108/EC as well as the Ecodesign Directives 2009/125/EC and 245/2009. The CE marking is therefore aprecondition for commercialization and operation of a product within the European Economic Area and is thus aprecondition for its use in that area.

The CE marking was created mainly to provide the end user with safe and electromagnetically compatible products on the free market within the European Economic Area (EEA) and the European Community (EC) within that area. The CE marking is therefore often referred to as a product's "passport" for the European internal market.

The proof of conformity may be generated by the manufacturer under his own responsibility and it is monitored and, where necessary, enforced penally by the national market surveillance authorities. In Germany, for example, the BNetzA (Federal Network Agency) is responsible for fulﬁ lling this role. OSRAM has used the expertise of an independent test institute in order to obtain this certiﬁ cation for POWERTRONIC

products.

The CE marking is not a quality or test mark and implies nothing in relation to the quality of the products labeled with it. Therefore it should not be confused with the test marks of independent testing institutes (such as ENEC, VDE or VDE EMC marks).

3.4. Energy efﬁ ciency certiﬁ cation

The classiﬁ cations of ballasts into a number of energy levels has been introduced by the CELMA association. CELMA is an umbrella organization of national manufacturers' associations for lighting and electro-technical components for luminaires in the European Union. CELMA has 19 member associations and represents over 1,000 businesses in 13 European countries. The manufacturers are mostly small and medium-sized enterprises with a total workforce of 107,000 employees and with total annual sales of 15 billion EUR. Amongst the aims of this amalgamation is the categorization of all control gear for HID lamps into energy classes in accordance with particular uniform criteria and to submit proposals to the European Union on energy classes that should not be permitted in the future for use in the EU.

All POWERTRONIC

ECGs are categorized in Energy Class A2 and fulﬁ ll all the efﬁ ciency requirements for control gear under the ErP Directive starting in 2017.

3.5. Other certiﬁ cations

Mounting on materials whose ﬂ ammability properties are unknown, where the temperature does not exceed 95 °C in normal operation or 115 °C under abnormal conditions or in cases of failure.

Max. casing temperature in the event of failure (e.g. 110 °C)

The WEEE symbol stands for "Waste Electrical and Electronic Equipment". It regulates the return and recycling of electronic products. The important central goals of this initiative are the prevention of electrical and electronic scrap and the reduction of waste by recycling.

ECG LABEL

4. ECG label

Illustrative example using PTi 70/220-240 S

ECG description

Lamp types to be used

Quality marks, conformity and classiﬁ cation

Illustrative example using PTo 100/220-240 3DIM

Mark indicating the t

test point

Permissible t

and tc temperature values

Connection schematic Mains side

Connection schematic Lamp side

Installation information

Connection schematic Lamp side

Installation information

Connection schematic Mains side

Lamp types to be used

ECG description

Marking indicating the t

test point



Quality marks, conformity and classiﬁ cation

THE SYSTEM+ GUARANTEE/FURTHER INFORMATION

5. The System+ Guarantee

The OSRAM System+ Guarantee

Where POWERTRONIC

/NAV® high-pressure discharge lamps by OSRAM are

HCI used together, OSRAM gives a full 5-year guarantee for POWERTRONIC

for HQI Guarantee to apply, the relevant lighting installation must be registered with OSRAM.

/HCI®/NAV® products. In order for the System+

electronic control gear and HQI®/

products and a full 1 or 2-year guarantee

6. Further information

For more information and typical applications go to www.osram.com/system-guarantee

Datasheets, type lists and speciﬁ cation texts, as well as other information on the topic of POWERTRONIC can be obtained from the following website: www.osram.com/powertronic

GLOSSARY OF KEY WORDS

7. Glossary of key words

3DIM DALI®, StepDIM and AstroDIM

CT Color temperature

DA DALI

EMC Electromagnetic compatibility

EoL End of Life

ETA Lamp luminous efﬁ cacy

ETA sys Luminous efﬁ cacy of lamp + control gear

HCI Metal halide lamp with ceramic burner

HQI Metal halide lamp with quartz glass burner

HS High-pressure sodium lamp

MH Metal halide lamp

NAV Sodium vapor high-pressure discharge lamp

PFC Power factor correction

PHI Luminous ﬂ ux

PL Lamp wattage

PS Wattage of system (lamp + control gear)

Ra Color rendering

SD StepDIM

Ambient temperature

Temperature at tc point

www.osram.com/powertronic

www.osram.dewww.osram.

OSRAM GmbH

Head Office

Marcel-Breuer-Strasse 6 80807 Munich Germany Phone +49 (0)89-6213-0 Fax +49 (0)89-6213-20 20 www.osram.com

Customer Service Center

(KSC) Germany

Albert-Schweitzer-Strasse 64 81735 Munich Germany Phone +49 89-6213-60 00 Fax +49 89 6213-60 01

01/13 Subject to change without notice. Errors and omissions excepted.

OSRAM POWERTRONIC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual