LG PSF1032A User manual

PLS (Plasma Lighting System)
SERVICE MANUAL
Caution: Please read the “Safety precaution” before repairing the product.
Model: PSF1032A

2
Contents
1. Safety precaution ....................................................................................... 3
2. Product specification ................................................................................. 4
3. Exterior and name ...................................................................................... 5
4. Installation environment and method
■PSF1032A installation environment guide ............................................ 6
■Installation method and example ..................................................... 7~10
■Example of incorrect installation .......................................................... 11
5. Operating principle and description
■Block diagram .................................................................................... 12
■PLS operating order .......................................................................... 13
■Drive PCB diagram ...................................................................... 14~15
6. Troubleshooting
■Error mode and action ........................................................................16
■Error check mode and resolution ..................................................... 17
■Error cancelation method .................................................................. 17
7. Disassembly diagram ............................................................................ 18
8. Replacement parts list ........................................................................... 19

3
1. Installation and repair/check precaution
• Never disassemble the product unless done by specialized service technician.
(It can cause safety accidents such as electric shock or fire.)
• When servicing the product, unplug the power cord and make sure that the power is completely disconnected.
• When repairing or checking the PLS product immediately after operating the product, wait until the system is
cooled sufficiently.
• If PLS is abnormally turned off, always handle the product after disconnecting the power.
(It can cause electric shock or leakage of electromagnetic wave.)
• If the product is wet, always wipe out the moisture before working on the product.
• Clean the front cover glass periodically to maintain the illumination.
• Do not directly look into the bulb while the product is operating. The strong light can cause visual defect to the
eye.
2. Check grounding
• Before working on the product, check whether the product is grounded and make sure to ground the product if not
done so.
3. Electricity connection test for troubleshooting
• Install the repair jib on flat floor and mount the PLS product, and then connect the power.
• Do not leave any flammable material around the product and keep a safe distance as defective parts can heat up
to start a fire.
• Because the heat can be concentrated on the illuminated area, keep more than 30cm of distance from flammable
material or from the floor.
4. Check and replacement method for electric parts
• When checking the electric part immediately after disconnecting the power, discharge the high voltage part of the
PCB before doing so. (High voltage capacitor and lightron high voltage charge can cause electric shock.)
• When the electricity is connected, never touch the power circuit.
(High voltage of DC 3500V~4000V is generated on the high voltage part.)
• Do not use parts that do not comply with the specification. (It can cause an error.)
• When there is an issue with the power circuit, it is difficult to replace the individual parts installed on the PCB.
Therefore replace the entire power supply.
※Caution: When using devices such as tester to check for error, always disconnect the electricity before using.
5. Electricity/ peration test after repair
• Never operate the product when it is not fully assembled such as lightron disassembled and waveguide separated
etc. It can cause strong leakage of electromagnetic wave.
• Connect the electricity in normal condition after sufficiently checking the electric/mechanical assembly of parts,
wiring condition and grounding connection etc.
6. Correct installation and grounding check
• After repairing the PLS product, clean the exterior and interior of the main unit and check the grounding condition.
And then install the product in its original position.
1. Safety precaution
Caution: PLS product operates at high temperature and generates high voltage at the power
supply. Because it can cause serious injury such as electric shock or burn when
handling the product, please read follow the check order as shown below.

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Rated voltage (AC)
Rated current (AC)
Power consumption
High frequency output (Microwave)
High frequency
Lightron
ptical speed
ptical efficiency
Color temperature
Color rendering index
Dimension (L x W x H)
Weight (kg)
Fuse
Thermostat
Thermistor
Input current check
Abnormal voltage
detection
Safety
device
Characteristics
Single phase 220-240 V / 50 Hz
4.7A ±5%
1,000W
450 W
2450 MHz ±50 MHz
2M214.A03GPTF
85,000 lm
85 lm/W
4,500 K 5,500 K 7,500 K
80 Ra
L570 x W440 x H680 mm
21 kg
Block overcurrent above specification: 250 V, 10 A
Prevent overheating of LTN: 130 ˚C / 70 ˚C
CLASSIFICATION SPECIFICATION
2. Product specification
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14 • ptical spectrum near natural light (Comfortable lighting)
• Lighting speed of 20 seconds
• Long life with high optical speed and high color rendering
• Environment friendly lighting device with high energy efficiency
※Above specification and safety circuit may change without separate notification.
Prevent overheating of power supply module: 75 ˚C
Detect oscillation of lightron
ver: 264V or above
Under: Block system when 176V or below

5
Case, Upper
Glass, Cover
Cover, Top
Case, Lower
Bolt,
Aiming Angle
Cover, Front
Tilt, Swivel
Power Supply
Cover, Side
Cover, Back
Cable,
High Voltage
Power Cord
(Plug-less)
3. Exterior and name

6
4. Installation environment and method
▣PSF1032A installation environment guide
[● : Can be installed, ▲:Request for consultation, ×:Cannot be installed]
※To maintain safety of high voltage power and to prevent malfunction, connecting the grounding cable to
each PLS set.
※Above conditions related to power must be complied. If changes are required, please contact LG for
consultation.
Installation environment PSF1032A
Application
classification
Power
supply
Temperature range of use (˚C)
Humidity range of use (%)
Indoor installation (Fixed downward)
Plant
Indoor gym
Warehouse
High rise building (Indoor)
Large building (Indoor)
Square or play field
Park
Large bulletin board
Large wall
Bridge
Environment with high temperature and humidity
Environment with use of gas
Area with vibration
Area with metallic dust
perating time of 24 hours/day
perating time of 16 hours/day
perating time of 10 hours/day
perating time less than 10 hours/day
Area difficult for A/S
Wireless LAN
Input power condition
Power wiring (mm2/unit)
Wiring per switch
Circuit breaker capacity (Per unit)
Main wiring (mm2)
- When wiring 2 units
- When wiring 4 units
- When wiring 6 units
- When wiring more than 6 units
-20 ~ +40 ˚C
80% or less
×
●
●
●
●
●
●
●
●
●
●
▲
×
▲
▲
▲
●
●
●
▲
●
Single phase 220V ±15%
2.0 mm2or above
3 or less
10A or above
–
3.5 mm2or above
5.5 mm2or above
8.0 mm2or above
Request for consultation

7
1) This model (PSF1032A) is designed to be installed outdoors and supports day to day water proofing.
2) To prevent the product from falling by wind or other external force, use the bolt and nut of M8 or above.
3) Be careful not to let other objects interfere with product from cooling and also be careful not to block the
inlet/outlet when installing the product.
4) Installing the product in an environment that exceeds the usable temperature and humidity can cause
unexpected issues. Therefore always consult with LG Electronics before installing the product.
5) Installing the product in locations where chemicals such as TCE series or chlorine gas are used or
locations where vibration is excessive can cause unexpected issues. Therefore always consult with LG
Electronics before installing the product.
6) When using the product in highly dusty area, the illumination can be reduced due to the dust. Therefore
periodically clean the product and do not install the product where metallic dust is generated.
7) Install at least 1m from the ground clearance distance must be maintained.
8) The mark means min. distance from PLS to lighted object when install the PLS, check the distance from
PLS on the optical axis of PLS.
▣Installation method and example
※※
Product size
(Units : mm)
3m
1. Follow regulations of government agency for technical standard and electric power company's guide
regarding regulations on equipment and wiring.
CAUTION
2. Do stated earth work when installing PLS
• Do earthwork of PLS. Do not connect earth wire with gas pipe, water pipe, lightning
rod or telephone line. It can cause electric shock as it makes earthwork incomplete.
WARNING
WARNING
• By the regulation and this installation guide, electric work using a specific circuit must
be done by certified electric technician. It can cause fire or electric shock if capacity of
power supply circuit is insufficient or faulty.

8
※※
Power condition and switchboard configuration for PLS installation
• Because the power consumption per 1 set of PLS is high, the cross sectional area of the
switchboard must appropriately be applied, and for stable operation, one control switch must be
installed for each set.
• Grounding requires more than 3 grounding points and must be wired for safety purposes.
PLS switchboard
(When installing 6 sets)
Apply
14.0 mm
2
or above
MCCB
75A or
above
Apply 2.0 mm
2
or above for
each line
Recommended to
apply ELB, MS
capacity of 10A
Note)
MCCB: Molded Case Circuit Breaker
ELB: Earth Leakage Circuit Breaker
Use rate sensitivity current (Break current) of 30 [mA]
MS: Magnetic Switch (Used when applying GPS or auto flash device)
* PLS is not equipped with a terminal block. For installation, please get professional assistance.
- Terminal Block Specification
(a) Rated Voltage: 250V or above
(b) Rated Power: 10A or above
(c) 3 way bolt fastening type
- After connecting power line to the terminal block, ensure that the power line makes secure
contact with fastening bolt or clamp and the power line is securely fastened.
WARNING
• After wiring power line to terminal box, check if the line touches tightening bolt or clamp or
is being forced.
• Use regulated electric wire so connecting part of terminal is knocked out by external force.
It can cause fire if connecting part is fixed tightly as it generates heat.
• Wire power line after ring terminal work. It can cause fire and failure of electric parts.
• Check Neutral status when installing main power
• Ending part of PLS has to be waterproof when connecting it to terminal.

9
※※Lower Case and Base Plate size
Case Lower
– Refer to the dimension of the case below the power supply and fixate the product.
Base plate to fixate product (Separately manufactured)
– Considering the safety of the system and installation, it is recommended to manufacture the
base plate separately to fixate the product. Refer to the following drawing.
(Not included in the product)
– If the base plate is not required, install the product by considering the cooling path
(Inlet/ utlet) of the system.
▶When manufacturing the base plate to fixate the
product, always use steel plate of L400xW272 (mm)
5T or above.
(Units : mm)
231
252 13
10
59 70 40
400
110
255,0
400,0
12,0
80,0
30,0
80,0
30,0
80,0
50,0
30,0
30,0
(Units : mm)
Inlet
utlet
Bolt/Nut connection
(Hole with width of 10mm)

10
※※
Installation example
ptical source
(LDM)
M8 Bolt
Bolt,
Aiming Angle
utlet
Spring
Washer
M8 Nut
Base plate to
fixate product
Base Plate
Power supply
(PSM)
Inlet
• Install the product on even ground free from submersion.
• When adjusting the bolt (M12 bolt, aiming angle) to adjust the PLS angle, always use a spanner
and maintain torque of 40kgf.cm or above.

11
※ Below shows the example of incorrect application/usage. Be careful with installation and usage
in the following cases as it can cause electric shock, injury, burn etc.
No. Example of incorrect application and usage Expected risk
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
When using with impact, such as product falling, applied on product
When using with switchboard below rated current capacity
When product is disassembled and reconfigured arbitrarily
When installing/using product without securing space to cool the product
When fixed/used loosely without considering the installation board, product weight/vibration etc.
When installing, repairing and checking the product in an environment where water can penetrate into the
product. This product can be used for underwater lighting (Underwater scenery, exploration, event usage etc.)
When using the PLS product without repairing after submersed under water
When using the product in condition with excessive power voltage variance (Above ±15%)
When using the product without grounding
When excessively bend the power cord or using damaged power cord
When inserting any pin, coin or metal wire into the internal/external hole on the case
When putting a cover on the exterior of the product for use without considering the suction inlet/exhaust outlet
When using the product with flammable material around the product
When disassembling while the product is operating
When repairing or disassembling the product by an unqualified technician
When using in environment where alien particles penetrate into the suction inlet/exhaust outlet
When cleaning or repairing the product while operating the product
When touching the power cord with wet hands
When using the product for purpose other than lighting (Heating food, drying clothe, heating etc.)
When moving the product by holding the part other than the main unit (Moving by holding the reflector etc.)
When moving the part without caution not considering the weight of the product
When not wearing any safety gear when contacting the hot part (Cover glass, reflector etc.)
When using the product near a heating device
When installing and using the product near areas with risk of flooding
When cutting and using the power cord arbitrarily
When making body contact on the product when it is hot while operating or immediately after operating
When installing and using the product in areas not properly ventilated
When using underwater
Fire/Electric shock
Fire/Electric shock
Fire/Electric shock
Fire
Injury
Fire/Electric shock
Fire/Electric shock
Electric shock
Fire/Electric shock
Fire/Electric shock
Fire
Fire/Electric shock
Fire/Electric shock
Fire/Electric shock
Fire
Electric shock
Electric shock
Fire/Electric shock
Injury
Injury
Injury
Fire/Explosion
Electric shock
Fire/Electric shock
Injury
Fire
Electric shock
▣Example of incorrect installation
Electric shock

12
5. Operating principle and description
▣Block Diagram

13
▣PLS operating order

14
▣Drive PCB diagram
P800 AC 220V input
L D700/701
DC/15V/24V power L D
P901
DC fan connector
P900
SYS, fan, bulb MTR connector
VR800 output volume control
P301
xt. PGM loading terminal
L D 300 error display
S300 error cancel switch
P601 high voltage earth
terminal
P600 high voltage (4kV)
terminal
※※
PSF1032A PCB ASSEMBLY INVERTER

15
L D error display
No. 1: Input voltage error
No. 2: BLDC error
No. 4: Input current error
No. 5: Inverter internal temperature error
※※
PSF1032A LED error display

▣Error mode and action
Does not
light up
initially
Lamp goes
off trying to
turn on
Lamp is dark
Check whether the power
cord and other internal
wiring is done correctly
Check for any issue on L, N,
GND and internal wiring
Check wiring based
on installation
standard and internal
wiring
Check whether the fuse is
disconnected
Separate the noise filter box of
the power supply and visually
check whether the fuse is
disconnected
Replace PSM (Power
Supply Module)
Check system power
consumption
After checking the power
consumption using the
measuring device, check
whether it is normal
If normal, replace the
bulb assembly
Replace generator
assembly
Check whether DC fan of
LDM part is operating
normally
Check system DC fan cable Connect the cable Replace DC fan
Check error check mode:
Flash error LED 1 time
Check error check mode:
Flash error LED 2 times
Check the input power voltage
Check whether BLDC rotates Replace bulb assembly
Connect the cable
Check BLDC cable wiring
Error mode
* Caution: First, check whether the power cord is unplugged from the outlet and then check/repair
according to the safety precaution and procedure.
Check point Check method Action item 1 Action item 2
(If not resolved by action item 1)
16
6. Troubleshooting
Check error check mode:
Flash error LED 5 times
Check whether PSM cooling
fan is operating and whether
there is any issue with wiring
Connect the cable Replace DC fan
Check system power
consumption
Check the system power
consumption using the
measuring device
Replace PSM Replace generator
module
Check resonator condition Check if the resonator is
crushed or have any holes
Replace LDM (Light
Drive Module)
Check error check mode:
Flash error LED 1 time
Check input power voltage

17
▣Error check mode and resolution
1
2
4
5
Error LED on-and-off 1 time
( ●●●→)
Error LED on-and-off 2 times
( ●● ●● ●●→)
Error LED on-and-off 4 times
( ●●●● ●●●●→)
Line Voltage Error Check
(220V ±15% or more)
BLDC FG Error Check
(Less Than BLDC 1,400 RPM)
Input Current Error Check
(Unstable lightron oscillation)
Unstable input power voltage and
operation with overvoltage
Check whether BLDC is locked and
whether BLDC cable is connected
Check whether the lightron is operating
normally and whether the system fan is
operating
Check whether the PSM cooling fan is
operating
Error LED on-and-off 5 times
( ●●●●● ●●●●●→)
P/Supply Inne Temperature
Error Check
Error display Error detail (Check limit) Check point
▣Error cancelation method
Control PCB error
Cancel error using clear
switch
1. Turn on power line
2. Check error LED
3. Press the error clear switch for 2 seconds. (Wait until the flashing LED is turned off)
4. Wait 30 seconds after the power line is turned off. (Discharge fully)
5. Check for relighting
Cancel error using
power line
1. Turn on power line
2. Turn off power line between 3~5 seconds
3. Repeat 1~2 process 5 times.
4. Wait 30 seconds after the power line is turned off on the last 7th time.
(Discharge fully)
5. Check for relighting
Error
Code

18
7. Disassembly diagram
301
102
101
305
201
306
202
302
104
103
401
402
403
404
304
303
307
308
405
406
309
310

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Generator Assembly, Microwave
101 AEC70519301 Guide Assembly, Wave Waveguide Assembly, PSF10 EA 1
102 ADZ72910401 Generator Assembly, Microwave PSF1032A, 7500K EA 1
103 MAZ62067401 Bracket, Fan PRESS AL 1 Air Guide EA 1
104 EAL31553601 Fan Module 4715K 2.95kRPM DC 24V EA 1
Power Supply Assembly
201 EBR62853901 PCB Assembly NYX1k Inverter Assembly (BLDC & Filament Control) EA 1
202 EAL38070201 Fan Module 4710KL-05W-B40, 2.5kRPM DC 24V EA 1
203 EAD60973001 Cable Assembly
KR010816-01 2P Housing / Spade Terminal 1.21M 12Pin Black EA 1
Cover Assembly
301 ACQ75452201 Cover Assembly, Side PSF1032A EA 1
302 MBL62598101 Cap, Protector M LD IIR PSF10 Cable Box EA 1
303 MCK62733701 Cover, Side Casting ADC12 290 200 155 EA 1
304 MCK62733801 Cover, Rear Casting ADC12 200 200 63 EA 1
305 3043Z-FB02A Supporter Assembly Flood900 SP EA 1
306 3111300001A Case Assembly PSF09 EA 1
307 3110Z-L006A Case, Rear AL Diecasting EA 1
308 3550Z-T006A Cover, Top AL Diecasting EA 1
309 MDS39999701 Gasket, Packing Complex Plate & Waveguide EA 1
310 3550Z-F005A Cover, Front AL Diecasting EA 1
Generator Assembly, ptic & Guide Assembly, ptic
401 ABD72910201 Bulb Assembly, Motor PSF1032A, 7500K EA 1
402 5018Z-L001A Mirror Sintering Quartz D76 EA 1
403 4016Z-M001A Strap, Resonator SUS, ETCK(DEUCH) EA 1
404 AKD72909201 Resonator Assembly ALUMINUM5052 0.5t EA 1
405 MCK63206601 Cover, ptic SINTERING GLASS 370 320 EA 1
406 3035300002B Reflector Assembly Neo PSF10 10Deg EA 1
8. Replacement Parts List
L C N . PART N .
DESCRIPTI N SPECIFICATI N EA No.

※Service inquiry and contact
Tel : [phone]
Fax: [phone]
Address : PLS Part
76, Seongsan-dong,
Changwon-city, Gyeongnam, Korea
ctober, 2010
Printed in Korea
P/No.:MFL62883503