IREM EX-170 G/3-US User manual

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Electronic power supply
INSTALLATION AND OPERATION MANUAL
MAN0094/2

3
MAN0094/2
GENERAL PURPOSES Description.............................................................................................. 5
Block diagram ......................................................................................... 6
TECHNICAL SPECIFICATIONS
Technical specifications* ........................................................................ 7
FUNCTIONS AND CONTROLS Control devices ....................................................................................... 8
CONNECTION AND OPERATING INFORMATION
Receiving the unit ................................................................................... 10
Delivery arrangement ............................................................................. 10
Storage ................................................................................................... 10
Removing of package and handling ....................................................... 10
Installantion - environment...................................................................... 10
Warnings................................................................................................. 11
Feet mounting displacement................................................................... 11
Preliminary checks.................................................................................. 12
Preparing the cables for remote control operation.................................. 12
Connecting the input-output cables ........................................................ 13
Connecting the cable for remote control operation................................. 13
DIRECTIONS FOR USE Local operation through the front panel controls .................................... 14
Switching on ........................................................................................... 14
Changing the lamp current ..................................................................... 14
Switching off ........................................................................................... 15
Remote operation ................................................................................... 16
Switching on ........................................................................................... 16
Setting the lamp current.......................................................................... 17
Changing the lamp current ..................................................................... 18
Switching off ........................................................................................... 18
Overheating protection and alarms......................................................... 19
Fan replacement..................................................................................... 20
TROUBLESHOOTING Possible failures...................................................................................... 21
TECHNICAL DATA Suggested wiring diagram ...................................................................... 24
Overall dimensions*................................................................................ 25
* these sections have been modified with respect to the previous issue.
Table of contents

MAN0094/2 4
Caution !
You should read this manual before attempting any intervention inside the unit.
Thenoncompliancewiththeinstructionsgiveninthismanualcanleadtoserious
damage to the unit which in this case will invalidate the warranty.
Nocompensationor indemnityunderanykindwillbeacknowledgedforinjury or
damageduetouseormisuseoftheproduct,forpooroperationoftheappliances
connected to IREM product or for immediate or indirect damage caused to the
powered equipment.
During the warranty period the replacement of defective parts and maintenance
procedures will be exclusively carried out at IREM servicing centre.
Keep this manual along with the unit.
CE declaration is available on request.
Thismanualaimstogivesomeoperatinginstructionstotheuserinordertograntasafe
and optimal use of the unit.
Keep this manual along with the unit. You should read it carefully both for installation,
starting-up and maintenance procedures.
This manual is composed by the following sections:
. description
(product and application fields)
.functions and controls
(main characteristics and operation modes)
.connection and operating information
(directions for connection, start-up and use of the power supply)
.technical characteristics

5
MAN0094/2
Description
This electronic power supply for three phase 208VAC - 50/60Hz input, has been
designed to feed from 2000 to 7000W short arc Xenon lamps, meeting all the
requirements of lamp manufacturers to ensure correct operation, long life to the lamp,
and high reliability.
Thiscompactandlightweightpowersupplyhas beendesignedtomeettherequirements
of a unit to be installed inside a cabinet.
Its particularly compact design, the advanced circuitry and the displacement of input
and output terminal board and the lamp current adjustment make the unit suitable to a
wide variety of applications both in vertical and horizontal position and specifically:
-standard film projection
-theatre applications
-architectural applications
-solar simulations.

MAN0094/2 6
1. Input filter board
Limiting the high frequency interferences (complying with EMI/EEC Standards).
2. Diode bridge rectifier
Converting the alternated voltage from the mains into direct voltage
3. Inverter board
Designed in compliance with IGBT technology, H type full bridge configuration
4. High frequency transformer
Granting the galvanic insulation between input and output
5. Output rectifier circuit
Composed by two fast low noise diodes
6. Output filter
Granting the lamp ripple current value at <1% pk- pk.
7. Driving board
Driving and controlling the unit
8. Auxiliary powering board
9. Digital instrumentation
Displaying output voltage and current values
Block diagram

7
MAN0094/2
Technical specifications
Lamp capacity 2000W to 7000W
Nominal input voltage range 187-230V 3ph +N
Input frequency 47-63Hz
Insulation class CL1
Rated current (max.) 25A
Sinusoidal absorption not provided
DC output current 60-170A
DC max. voltage 47.5V
No-load voltage 140V
No-load voltage rising time 3 s
Ripple <1%
Efficiency 0.9
Output overload protection electronic
Lamp striking soft-start ignition current
Ventilation forced
Remote ON/OFF switching external switch
Igniter insertion control not provided
Lamp current remote setting 0÷10V control
Setting of lamp current limit provided
Output current stabilisation provided
Input circuit breaker provided
Input extra voltage protection provided
Lamp ON signalisation provided
Display signals mains ON
max. temperature
ON/OFF remote control
lamp max. current setting
digital ammeter to read output current
digital voltmeter to read output voltage
Safety standards EN 61204
EMC standards EN 50081-2 EN 50082-2 EN 50082-1
IEC 61000-6-2 IEC 61000-6-4
Markings CE, UL (for US market)
Operating temperature 0°C to 45°C
Storage temperature -20°C to +60°C
Protection degree IP00
Dimensions 255x475x420h mm
Weight 33 kg

MAN0094/2 8
Functions and controls
Control devices

9
MAN0094/2
1. ON/OFF switch
2. Mains input LED
3. Overtemperature LED
Lit in case of overheating
4. Lamp current selector
Permittingtoselectthemax.poweringcurrentinaccordancetothelampcapacity
5. Current LED
Highlighting the selected current range.
6. Lamp current potentiometer
Adjusting the lamp output current
7. Remote control connector
Connecting the remote control cable
8. Remote control selector
Selecting the ON/OFF switching and the lamp current directly on the unit or
remotely by means of the remote control device (0÷10V).
9. Remote control LED
Lit when the unit is on remote operation
10. Input circuit breaker
11. Input terminal board
12. Output terminal board
13. Digital instrumentation
Displaying lamp current and voltage values
Functions and controls
Control devices

MAN0094/2 10
Connection and operating information
Receiving the equipment
After receipt, check that the unit is in good condition. When necessary, contact the
forwarding agent.
Delivery arrangement
The supply consists of:
EX170-G/3 electronic power supply
a remote control connector
an installation and operation manual
a warranty card.
Storage
If the unit is stored before installation, check that it is kept dry and cannot come into
contact with water in any form. Do not expose the unit to the sun rays or other sources
of heat.
Package removing and handling
Remove the packing and keep it in case of future transportation needs.
Carefully lift the unit by means of its handles. Avoid any shock when moving.
Installation - environment
TheperformanceoftheEX170-G/3electronicpowersupply is
guaranteedforatemperaturerangevariablebetween0°Cand
+45°C. Check that the place where the equipment is to be
installed is sufficiently ventilated to prevent the air around the
unit from exceeding this limit. Avoid dusty environments.
Ensure that the ventilation slots are unobstructed.
To prevent blockages caused by excessive temperatures, do
not expose the unit to the sun rays or other sources of heat. 45°C max.

11
MAN0094/2
Warnings
Caution : dangerous voltages inside the power supply. Disconnect
the unit from the mains before checking the internal components.
Prevent water, liquids in general and/or foreign objects from getting
inside the appliance (do not open the unit, contact IREM servicing
centre !).
Installation must only be carried out by trained personnel .
Thecircuit breakerpowering cablesarelocated inthe lowerpartof the
unit (see label on the front panel).
If the plant is provided with an earth leakage circuit breaker having
a tripping value of 30mA, this breaker could trip when switching on
the power supply. This does not normally mean a failure, but is due
tothecapacitorsof the EMIfilter. Switch on the earthleakage circuit
breaker again to alleviate the problem.
Feet mounting displacement
EX170-G/3 electronic power supply is equipped with two fixing brackets that may be
used as an anchoring for the unit (B) or as normal feet when the unit is normally
displaced without any fixing (A).
If feet are used as fixing flanges, holes have to be done as per following picture:
Connection and operating information

MAN0094/2 12
Connection and operating information
Preliminary checks
Importantnote: the unit mayoperate withoutneutral lead.Nevertheless
werecommendtheneutralconnectionforabetteroperationoftheinput
filter board.
Connection must be carried out in compliance with the current safety standards.
Toensureacorrectoperationoftheunit,pleasestrictlyfollowtheserecommendations:
-the input powering has to be: 208V ±10%, 60Hz plus neutral and ground,
withstanding a current of 30A per phase
-the earth installation must comply with current standards
-the cables to be connected to the output terminals must have a size suitable to the
lamp power.
During connection pay attention to the lamp polarity.
Preparing the cable for remote operation
Make exclusive use of:
. a shielded cable having 4 poles minimum
. the connector provided with the unit.
Forconnectionplease referto thewiringdiagram andto pininstructions to befound on
front panel connector J1/A5.
For switching ON/OFF through remote control make use of a switch with insulated
contacts (1A/50V).
The unit is OFF when contacts are open
The unit is ON when contacts are closed.
The setting voltage of remote operation has to be within 0÷10V. Please refer to the
setting voltage tables on next pages.

13
MAN0094/2
Connect the input cables to the terminal board X1 (11).
Connect the output cables to the terminal board X2 (12).
Pay attention to lamp polarity and terminal identification:
Input terminals
U-V-W: phases
N: neutral (*)
PE: ground
*: if available
Auxiliary terminals
The lamp ON/OFF signalisation is obtained through a N.O. dry relay contact.
Max. withstanding capability: 0.50A / 250Vac
Output terminals
+: positive
--: negative
Connecting the cable for remote operation
Connect the shielded cable to J1 connector (7).
Connecting input/output cables
Connection and operating information
Lamp OFF
Lamp ON

MAN0094/2 14
EX170-G/3electronicpowersupply maybeusedeitherthroughthefrontpanelcontrols
(local) or through a remote control.
Local operation through front panel controls
Switching on
1. Make sure S1 switch (1) is set to 0 (open).
2. Make sure Q1 circuit breaker (10) is set to OFF (open).
3. Set the max. current selector (4) to the max. lamp capacity.
E.g.: 3000W lamp ----> max. current: 100A ----> selector set to 100A.
4. Turn the current potentiometer P1 (6) completely counter-clockwise.
5. Set the remote control selector (8) to OFF.
6. Check the input voltage is within the limits of the unit data plate (208V ±10%).
7. Set Q1 circuit breaker (10) to ON. The LED "mains input" (2) will light up.
8. Be sure the LED no. 5 (lamp max. current) is lit.
9. Set the ON switch (S1 - 1) to 1 position (closed).
10. Be sure the output voltage (to be read on the voltmeter - 13) is 130V ±10V
11. Wait 4 s max. then strike the lamp.
12. Gradually increase the output current through the potentiometer (6) till to reach
the desired value.
13. Set the current value through the ammeter (13).
Changing the lamp current
To change the lamp current act as follows:
1. Set S1 switch (1) to 0 (open).
2. Set the max. current selector (4) to the new current value. The corresponding LED
(no. 5) must light up.
3. Set S1 switch (1) to 1 (closed).
4. Wait 5 s then strike the lamp.
5. Gradually increase the output current through potentiometer (6) to have the desired
value.
Directions for use

15
MAN0094/2
Switching OFF
To switch OFF the unit act as follows:
1. Set S1 switch to 0 (open).
2. Set Q1 circuit breaker (10) to OFF (open).
Remark: if you open the circuit breaker and the lamp is OFF, you have to wait the
completeswitchingoffofthepowersupply(10sapprox.).Thenclosethecircuitbreaker
again to attempt a new ignition.
Directions for use
Local operation through front panel controls

MAN0094/2 16
Connect the interface cable to J1 (7) connector.
Switching on
To switch on the unit, please follow the instructions here below:
1. Be sure that the external switch is set to OFF (open)
2. Check that S1 switch (1) is set to 0 (open)
3. Check that Q1 circuit breaker (10) is set to OFF (open)
4. Set the max. current selector (4) to the power corresponding to the lamp max
capacity
E.g.: 3000W lamp ----> max current: 100A ----> selector set to 100A.
5. Turn P1 potentiometer (1) for current adjustment completely counter-clockwise.
6. Set the remote control selector (8) to ON.
7. Check that the input voltage of the power supply is within the preset limits as per
data plate (208V ±10%).
8. Set Q1 circuit breaker (10) to ON, and check that mains input LED (2) lights on.
9. CheckthatLED no.5(correspondingtothelampmaxcurrent)andremotecontrol
LED (9) are lit.
10. Close the external ignition switch.
11. Checkbymeansofthevoltmeter(13)thatthereisanoutputvoltageof130V±10V.
12. Wait 4 seconds max. before striking the lamp.
13. After lamp ignition, it is possible to set the desired output current by means of an
external signal 0-10V, following the instructions of the enclosed tables.
14. Check the desidered current value by means of the relevant ammeter.
Directions for use
Remote operation

17
MAN0094/2
100A (max. lamp current) 140A (max. lamp current)
Current (A) Voltage ( DC) Current (A) Voltage (DC)
55 ±24.55 ±0.1 55 ±23.70 ±0.1
60 ±25.20 ±0.1 60 ±24.10 ±0.1
65 ±25.70 ±0.1 70 ±24.90 ±0.1
70 ±26.20 ±0.1 80 ±25.60 ±0.1
75 ±26.70 ±0.1 90 ±26.40 ±0.1
80 ±27.20 ±0.1 100 ±27.10 ±0.1
85 ±27.60 ±0.1 110 ±27.90 ±0.1
90 +2 8.00 ±0.1 120±28.60 ±0.1
95 ±28.50 ±0.1 130 ±29.40 ±0.1
100 ±29.00 ±0.1 140 ±210.00 ±0.1
105 ±29.40 ±0.1
110 ±210.00 ±0.1
170A (max. lamp current)
Current (A) Voltage ( DC)
65 ±23.40 ±0.1
70 ±23.80 ±0.1
80 ±24.40 ±0.1
90 ±25.00 ±0.1
100 ±25.70 ±0.1
110 ±26.30 ±0.1
120 ±26.90 ±0.1
130 ±27.50 ±0.1
140 ±28.00 ±0.1
150 ±28.70 ±0.1
160±29.30 ±0.1
170 ±29.90 ±0.1
Directions for use
Setting lamp current values by means of 0-10V signal
Remote operation

MAN0094/2 18
Directions for use
Changing the lamp current
Tochange lampcurrent(e.g. toswitch froma 3000Wlamp toa 7000Wlamp) whenthe
unit is already on, it is necessary to carry out the following operations.
1. Set the external ignition switch to OFF (open)
2. Setthemax.currentselector(4)onthenewpowervalueandcheckthatthe LEDno.
5 lights up.
3. Set the external ignition switch to ON (closed).
4. Wait 5 seconds before striking the lamp.
5. Set the desired output current value by means of the 0-10V signal.
Switching off
To switch off the unit:
1. Set the external switch to OFF position (open).
2. Set Q1 circuit breaker (10) to OFF (open).
Remark: if you open the circuit breaker and the lamp is OFF, you have to wait the
completeswitchingoffofthepowersupply(10sapprox.).Thenclosethecircuitbreaker
again to attempt a new ignition.
The remote functions (switching on/off and lamp current adjustment)
can be used all at the same time or alternatively. This means that it is
possible to switch on the power supply directly from the control panel
and adjust the lamp current from remote and vice versa.
Remote operation

19
MAN0094/2
EX170-G/3electronicpower supplyisequippedwith overheatingprotectionand alarm
device.
Incaseofoverheating,theunitcutsofftheoutputpowering,avoidingpossibledamages
to the circuitry.
In such a condition, the LED "Overtemperature" (3) on the front panel is flashing.
SetS1switchortheexternalswitchforremotecontrol (accordingtotheoperationmode
selected) to OFF and set Q1 circuit breaker (10) to OFF.
The thermal protection tripping may be caused by:
1. Too high ambient temperature (max 45°C)
2. Overload in output
3. Insufficient air flow due to obstruction of air slots
4. Failure of the built-in fan/s.
In case of failure, contact IREM Servicing Centre.
Directions for use
Overheating protection and alarm