CLS40, CLS80, CLS90 Applications Manual

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1 CLS40, CLS80, CLS90 Applications Manual Prepared by: Steven Briggs Version Sep-2016 Tyler Close Normanton Wakefield WF6 1RL

2 Table of Contents Introduction... 3 Product Specification... 3 Connection diagram, DALI and 1-10V Dimming... 4 Dimensions and Fixing Centres... 4 Output Current Setting... 5 DALI, Touch Dim & Switch Dim Functions S2D... 5 Automatic Mode Selection... 5 DALI... 5 Touch Dim... 5 Switch Dim... 6 Analogue (0-10V,1-10V) Dim... 6 Breaker Information... 7 Input Overvoltage Withstand... 7 Thermal Protection... 7 LED Module Construction... 8 Wire Length... 8 Reliability... 8 Lifetime... 8 Typical Performance Revison History Contact Us Page 2 of 11

3 Introduction The CLS range of LED drivers provide a compact, low-profile and efficient solution for modern LED luminaires replacing traditional fluorescent form-factors. The CLS is available as fixed output, 1-10V dimming, DALI dimming and touch dimming controlled versions. Product Specification Model CLS40-350S2 -UNI- CLS40-350S2D -UNI- CLS40-350S2A -UNI- CLS80-350S2 CLS80-350S2D CLS80-350S2A CLS90-700S2 CLS90-700S2D CLS90-700S2A Switched Current Selection Analogue Dimming Control (1-10V) DALI Dimming Control Touch Dimming Switch Dimming Dimming Range N/A 1-100% 1-100% N/A 1-100% 1-100% N/A 1-100% 1-100% Input (Nominals) 120, , 277 Vac , 277 Vac Input (Maximum Range) Vac Vac Input Current (maximum) 0.45A, 0.25, 0.2A 0.45A 0.5A Input Power 46W max 90W max 100W max Leakage Current Power Factor (typical, full load) 0.99 (120 Vac) 0.97 (277 Vac) 0.97 Input Frequency Hz DC Operation Consult Harvard Inrush Current Typ 50A / <500us Surge Protection 2KV Differential, 4KV Common mode Output Current (Switchable) 350 / 300 / 250 / 200 ma 700 / 600 / 500 / 400 ma Output Current Accuracy ±5% 100/120Hz Output Ripple <2% Output Range Vdc (220V on Dali) Vdc Vdc (227V on Dali) Open Circuit 250 Vdc Max Output to Earth 420Vrms Thermal Protection Gradual reduction of output current above Tc=85C Terminals Push-wire for stranded or solid wire Wire size mm² Ingress Protection (IP) Classification 20 Standards Compliance EN :2008+A2:20013 EN :2014 EN :2014 EN :2013 EN61547:2009 EN55015:2006+A1:2009 EN62384:2006+A1:2009 EN :2009 EN :2009 EN :2009 Dali version higher voltage available on reduced current settings, see Output Current Setting Page 3 of 11

4 Connection diagram, DALI and 1-10V Dimming Connection DALI Touch / Switch Dim 1-10V Control 1 DA Live Switched 1-10V (control) Control 2 DA Neutral 0V (ground) NOTE:- 1) The LED output is NOT isolated from mains supply, and LED connections MUST be treated in the same way as mains wiring. Provision must be made to prevent accidental contact by service personnel (i.e. touch-proof connectors etc). 2) DALI or 1-10V control ports are provided with BASIC insulation to mains and output terminals. Both are often wired alongside the mains, or with mains & control multipole connectors, and as such should be treated as mains rated wiring with respect to safety. 3) DALI is not polarity dependent, 1-10V is polarity dependent. 4) Output between output terminals is up to 250V DC, but the potential of the LED+ terminal may be as high as 420V RMS with respect to earth. Wiring insulation on the LED side must thus be of the 600V category. Dimensions and Fixing Centres Page 4 of 11

5 Output Current Setting Output current can be set via the DIP switches adjacent to the output terminal block. The mains supply MUST be switched off before operating switches for your own safety. Use a suitable small, insulated tool. DIP Switch CLS40-350xxx CLS80-350xxx CLS90-700xxx 1 2 Current (ma) S2, S2A S2D S2, S2A S2D Current (ma) S2, S2A S2D Off Off Off On On Off On On For Switchable S2 units, the output current is fixed at the levels in the table. For DALI S2D units, the switches set the maximum current as per above table, the dimming is then pro-rata to the maximum current, i.e. if a driver is set to 200mA, then 10% dim level will be 20mA. However, the lowest current achievable is 1% of standard, full rated current, i.e. 3.5mA for 350mA unit, even if set to 200mA. Output figures in the above table are guaranteed maximum load voltage, so the designed LED string voltage should be less than these figures under worst case conditions (i.e. highest LED voltage Vf bin, minimum temperature). Typical open circuit voltage is 5V higher (±5V) than the above guaranteed maximums. DALI, Touch Dim & Switch Dim Functions S2D Current S2D drivers, fitted with a 2 pole RED DIP switch, support automatic selection of DALI, Touch Dim or Switch Dim depending upon the nature and behavior for signal connected to the dimming port. For older units fitted with a 4 pole BLACK micro DIP switch, please contact Tech Support for V1.2 of this manual. Automatic Mode Selection Selection of DALI, Touch Dim or Switch Dim is automatic depending upon the nature of the signals present on the control port. Mains power to the driver will need to be removed for >20 seconds if changing control modes (i.e. DALI to Touch/Switch Dim and vice versa). DALI The CLS is compliant to DALI (Digitally Addressable Lighting Interface) standard EN62386, acting as Device Type 6 (LED Module). The DALI control bus should be connected to the DA terminals on the driver. Polarity is not important. Touch Dim Touch Dim provides a simple dimming facility that can control multiple units in parallel, giving on/off and dimming control by means of a single switch. The mains supply voltage is permanently Page 5 of 11

6 connected to the driver, while the control inputs (DA/LS, DA/N) are connected to mains via a momentary (i.e. non-latching push-to-make switch or similar). A short push of the switch will toggle the light on or off. If the switch is held on, the light will fade up or down, alternating direction with each push of the switch. Touch Dim Operation Contact Duration Driver Response Ignore 0 to 40ms Ignore Short push 40 to 400ms Toggle on/off Long push 400 to 10,000ms Dim up or down Reset push >10,000ms Driver Reset If the mains supply is interrupted, the driver will restore the previous condition (light on/off status, level and fade direction) when the mains supply returns. If a lighting system is extended, modified or otherwise disturbed, it is possible drivers may no longer be synchronized for light state, level or direction. To solve this problem, all drivers on a system can be reset to the same state by pressing the control switch for longer than 10 seconds. At 10 seconds, all drivers will jump to 50% output and next fade direction will be downwards. Switch Dim Switch dim is useful for areas of low or occasional occupancy, i.e. corridors and such like. Usually, a switched mains signal is taken from a PIR occupancy sensor to the control inputs (DA/LS, DA/N) of the driver. With no signal present, the driver will output 10% current. When triggered by the sensor, the driver will quickly fade up the lights to 100%, and remain at 100% while the control input is activated. When the control signal terminates, the lights will slowly fade back to 10%. In order to activate switch Switch Dim, the control input must be held active (with a mains signal) for greater than 4 minutes. The driver will then switch to, and subsequently remember, it is in Switch Dim mode. The activation can be easily achieved, by for example, walking around the area and keeping the PIR sensors activated for that period of time. Should a driver accidentally get into Switch Dim mode on a Touch Dim system, then 3 very brief button presses in less than 2 seconds will clear the driver back to Touch Dim mode. Analogue (0-10V,1-10V) Dim This is a traditional way of controlling lighting systems. The output of the driver may be adjusted between 1% and 100% output by application of 1-10V control signal. The control interface meets the requirements of IEC60929 Ed 3 Annex E. Between 0 and 1V : Output current is Minimum Between 1V and 10V : Output current varies linearly between minimum and 100% Between 10V and 11V : Output current is 100%. Page 6 of 11

7 The CLS driver sources uA at its dimming port terminals, so the dimmer must be capable of sinking this current, or the combined current of multiple drivers connected in parallel. Unfortunately, not all 1-10V dimmers on the market are fully compatible with the standard, so operation should be checked prior to final specification of an installation. The driver may be compatible with systems classed at 0-10V, although the dimmer needs to be capable of sinking current (i.e. current flow FROM driver TO dimmer). Breaker Information The maximum number of drivers that can be powered from a single breaker is based on a minimum mains voltage of 198Vrms or 108Vrms. Unit B6 B10 B16 C6 C10 C16 CLS80, CLS V CLS40, 240/227V CLS40, 120V Input Overvoltage Withstand The maximum input voltage the unit is guaranteed to meet specification is 305Vrms. Above this voltage the limitation is the Dependent Resistor (VDR) across the live and neutral inputs, this has a rated voltage of 320Vrms and starts to conduct significant currents above 350Vrms, testing has shown they will fail destructively at around Vrms causing the input fuse to fail. The VDR is fitted to attenuate lightning induced surges i.e. the electromagnetic field from lightning discharge induces a very short high voltage low impedance pulse on the mains supply. Thermal Protection The CLS80 incorporates an internal temperature sensor the will gradually reduce the output current, thus reducing the dissipation in the driver and especially in the associated LEDs and luminaire housing. Page 7 of 11

8 When used as intended as an integral (built in) driver to a luminaire, the thermal control will help protect both the driver and the LED s from excessive temperature conditions. LED Module Construction As the output of the driver is a HAZARDOUS voltage, as it is not isolated from mains, care should be taken in the design of LED Module ( Light Engine ) to ensure safety compliance. Adequate creepage and clearance distance for 420Vac rms to earth potential must be provided. This means 4.2mm minimum from tracks to any earthed element. Particular attention should be given to the edges, cut-outs and holes within metal core PCB designs to ensure creepage distances are maintained. The dielectric layer of the LED Module metal core PCB shall be adequate. Any suppression capacitors fitted on the LED module from LED circuit to earth will need to be safety approved Y2 class capacitors. Such capacitors will contribute to earth leakage (touch) currents and should be kept to a minimum. As the CLS80 does not provide isolation from the mains supply, any mains bourn surges or transients, particularly common-mode (i.e. to L/N to earth), are likely to be imposed upon the LED Module. Wire Length It is not recommended to exceed 2m of wire length between the CLS80 driver and associated LED modules. Wiring shall have adequate insulation for the voltages present, i.e. generally 600V grade wire is necessary. Reliability MTBF (Mean Time Between Failures). The MTBF calculated using MIL-HDBK 217F is around 111,600 hours with the driver with an ambient temperature of 50 C (Tc =75 C). Experience has shown that predictions using this method tend to be pessimistic with the real MTBF substantially longer. MTBF figures are very dependent on actual service conditions especially temperature and humidity and are almost impossible to predict with any accuracy. Lifetime Whilst the MTBF calculation deals with the random failures in a field population the lifetime looks at component wear out. In the CLS drivers the main components of interest are the electrolytic capacitors where the dielectric liquid within the capacitors migrates slowly over time as its molecules permeate through the seals around the leads. As a rule of thumb the rate of evaporation doubles with every 10K rise in temperature. Page 8 of 11

9 The high quality capacitors used within the CLS range have a minimum life of 8,000 hours at 105 C. Capacitor manufactures deem end of life when their capacitance has fallen by 20 or 30% (depending on manufacturer) from their initial value. Based on measured temperatures and ripple current factors, the lifetime of the electrolytic capacitors has been calculated as follows :- CLS40 Ambient Case Lifetime, Lifetime, Hours Temperature Tc 12hrs/day 30 C 55 C C 65 C C 75 C CLS80 / CLS90 Ambient Case Lifetime, Lifetime, Hours Temperature Tc 12hrs/day 30 C 55 C C 65 C C 75 C Page 9 of 11

10 Power Factor Efficiency % Typical Performance 96 CLS80 Efficiency Vac 230 Vac 300 Vac Number of Series LED Load 1.00 CLS80 Power Factor Vac 230 Vac Vac Number of Series LED Load Page 10 of 11

11 Revison History Rev Date Change By /05/16 Various SB /09/16 Updated breaker info SB Contact Us Address: Harvard Engineering PLC, Tyler Close, Normanton, West Yorkshire, WF61RL, United Kingdom. Website: Telephone: +44 (0) E&OE Page 11 of 11

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