Lumina Power XLB-3000 User manual
1
2
Product Overview 3
Explanation of Symbols 4
Theory of Operation
XLB-3000 Specifications 7
XLB-3000 Interface 10
Installation and Operation 12
!"#
!"#$ XLB-3000 Block Diagram 6
!"#% XLB-3000 Chassis Outline Drawing 8
!"# XLB-3000 Igniter Drawing 9
$ XLB-3000 Interface 10
!"#& XLB-3000 Interface Schematic 11
!"#'
XLB-3000 Input and Output Connections 12
!"#(
XLB-3000 Lamp Connections 13
%
XLB-3000 Current Control 1
XLB-3000 AC Input Requirements 1
3
)#*++!,
The XLB-3000 Xenon lamp ballast is a very compact power supply designed for OEM
applications. The XLB-3000 is ideal for high power applications where economy is
important and performance cannot be compromised. Compact size is possible due to a
low-loss Zero Voltage Switching inverter and incorporation of planar magnetics. Power
factor is greater than 0.99 and conducted emissions meet stringent European regulations.
No additional line filter is required to meet EN 011 emission requirements. Lumina
Power’s XLB series sets the standard for reliable lamp ignition and long-term high-power
operation in a low cost, compact package. The XLB-3000 is ideal for medical, projection
and industrial applications where a stable light source is essential.
As a Xenon lamp ballast, the XLB-3000 power supply first ignites the lamp with a high
voltage pulse and, once the lamp is ignited, acts as a programmable current source
delivering constant current based on the input program signal, Iprog (+), which is normally
0-10V. The XLB-3000 can be configured for output current up to 102A. Maximum
output voltage is 3 V. Typical lamp voltages are between 20V and 30V.
The XLB-3000 utilizes a proprietary low loss, high frequency power factor correction
circuit which keeps power factor above 0.98. Power factor corrected power supplies use
up to 30% less input current and meet stringent IEC harmonic requirements. The output
inverter is a state-of-the-art zero voltage switching (ZVS) inverter which permits very
high frequency power conversion with minimum losses and electromagnetic noise.
4
-!.
/01 This equipment produces high voltages
which can be fatal. Only service personnel of Lumina
Power, Inc. are qualified to service this equipment.
/!"2")1 This power supply
produces lethal high voltages. Only service personnel
of Lumina Power, Inc. are qualified to service this
equipment. Only qualified service personnel are
permitted to install this power supply.
.*!
3 !"#$4
The XLB-3000 Xenon lamp ballast has been designed for OEM Xenon lamp industry.
With this in mind, the Xenon lamp industry has the following requirements:
• Safe lamp operation
• Reliable short pulse lamp ignition
• Compact size
• Power factor correction to conform with CE requirements
• Low conducted electromagnetic emissions
• Low leakage for medical applications
Referring to Figure 1, the XLB-3000 BLOCK DIAGRAM. The following is a brief
description of operation.
5#),!#!.
AC input power is processed through a line filter to reduce the conducted EMI to an
acceptable level. The XLB-3000 line filter has minimum capacitance to ground to
minimize leakage currents.
), !5+
The rectified input power is next applied to power factor boost inverter. This inverter
boosts the input voltage to 400VDC. In the process of boosting the input AC voltage, the
input AC current is adjusted so that is always in phase with the input AC voltage.
Without this power factor correction circuit, the AC input current would be delivered to
the power supply in high amplitude, narrow spikes, having a high harmonic content. With
power factor correction, the non- 0/60 Hz harmonics are reduced to near zero. Since only
the fundamental frequency is now used to deliver power, the efficiency of the power
supply is improved considerably.
One problem with standard input power factor correction circuits is that a high frequency
switching circuit is placed across the line in the input side of the traditional input capacitor
filter. This circuit results in substantial switching noise conducted to the line. Lumina
Power employs a proprietary soft-switching boost inverter which produces minimum
switching noise, reduces switching losses, and results in a smaller heat sink associated
with the power factor circuit.
62",!!"36245+
The ZVS inverter and the output transformer are used to step the 400VDC bus down to
the appropriate output value. The ZVS inverter is the most modern high frequency/low
loss/low noise topology utilized in power electronics today. Instead of running the
inverter in a traditional PWM mode, the inverter is run in a phase shift mode. With the
appropriate output inductor and the appropriate capacitance across each switching device -
in this case MOSFETS - there are virtually no switching losses in the inverter. The only
losses in the devices are I2R losses associated with the Drain/Source resistance of the
6
MOSFETS. Therefore, the ZVS inverter also contributes to reduced losses, reduced EMI
noise and a reduction in overall system heatsink requirements.
*##!#!
The output filter is a single stage RC filter designed to keep ripple and output noise very
low.
!#!
The control circuit handles all the functions associated with safe operation of the Xenon
lamp. Reliable lamp ignition as well as tight current regulation, overvoltage and over
power protection are controlled and monitored in the control circuit.
#-!!.),
All internal power supply requirements as well as the external +/-1 V and + V power
supplies are derived from the power factor control boost inductor. All auxiliary power
supplies are regulated by standard linear regulators.
5"!#
The igniter module provides the 40kV pulse required to break down the Xenon gas and
facilitate ignition. In standard configurations, the pulse is applied through the positive
output to the lamp anode. Power to the module is provided by the main power supply
chassis. Internal circuitry in the igniter module senses the presence of the high voltage arc
and briefly disables operation in the main power supply chassis in order to minimize
damage from high voltage noise.
!"#$
78!"
7
99!:!
XX = Ioutmax YY= Voutmax
)
#-
5#-
5#2" !03-;-/4
XLB-3000-XX-YY 3000W
Configurable to
120A
200-240VAC 13” x 8. ” x 3.43”
33cm x 21.7cm x 8.71cm
-2"13 V
#-!!.*## : +1 V @ 0.20A
5#
Voltage: 200-240VAC, 0/60 Hz, 18. A @ 208VAC
Power Factor: >.98
5
(See interface description page 3)
Connector: 1 Pin D-Type Sub Female
5"!!<
Boost Voltage: 2 0V
Boost Energy: 00 mJ
Ignition Voltage: Up to 4 kV (~1us rise time)
Igniter Polarity: Positive or Negative (Factory Set per customer request)
Ignition Energy: 6 mJ
Igniter Dimensions: . ” x 3.6” x 2.6”
140 x 92 x 66mm
)
Line Regulation: <0.2% of maximum output current
Current Regulation: <0. % of maximum output current
Current Ripple: <0. % of maximum output current
Power Limit: Limited to maximum power with powerfold-back circuit
+!
Operating Temp: 0 to 40oC
Storage: -20 to 8 oC
Humidity: 0 to 90% non-condensing
Cooling: Forced air
"#.
Leakage Current: <3 0uA
+1
Medical Safety: UL60601-1, IEC 60601-1, EN 60601-1, CAN/CSA C22.2 No. 601.1-M90
Emissions/Immunity: FCC 47 CFR Class A Emissions, EN 011:1998 Group 1 Class A Emissions,
EN61000-3-2 Limits for harmonic current emissions, EN 610000303 Flicker,
EN60601-1-2:2001 Electromagnetic emissions and immunity for medical
equipment
8
!"#%
!*#!8,!"
3 8#.4
9
10
995
.1$'!8#
(Refer to Figure 4 XLB-3000 Interface Schematic)
)!
#
)!
#!
2"+
8!!
1
*<*=
(input)
(Note: 1)
High=RUN= V to
1 V
Low=OFF=0V
The *<*= function is the control function
which turns the lamp on and off. When the
lamp is turned on, a trigger and boost sequence
will ignite the lamp and deliver current as programmed
via Iprogram, Pin 7.
2
No
connection
Do not
connect
3 57
(input)
Open=OFF
Connect to
GND=RUN
The 57 function can be connected to external
interlock switches such as doors or over temp switches.
4, 9, 1 >8
2#
!:
(output)
0–10V=Vout max The output voltage of the supply can be monitored by
2#
!.
6
5#
!
(output)
0–10V=0–Iout max
The output current of the supply can be monitored by 5#
!
.
7 5"
3?4:
(input) 0–10V=0–Iout max
The power supply output current is set by applying a
0-10V analog signal to 5"
3?4 . Note that with 5"
3?4
set between 0V and 2V, when the lamp is turned on via
*<*=, the XLB-3000 will deliver 20% of the
maximum current rating of the unit. This is the minimum
current required to keep the lamp on. To deliver more
than 20% of the maximum rated current, (+) must
5"
be set higher than 2V. 1#.,!!
,!",@-!#+#
8
*<*=
#
(output)
Low=Lamp On
High=Lamp Off
The lamp status is monitored and if at least 20% of the
rated current of the power supply is flowing through the
lamp, the *<*=# signal will be pulled
low. When the lamp is off, this pin is pulled high to 1 V
through a 10K resistor.
10, 11,
12
No
connection
Do not
connect
13, 14
?$'2
AB%'
(output)
Auxiliary +1 V power supply for user. Up to 0.2 A
output current available.
$15
11
995!
!"#&
12
5!*!
!!7#!,!:"#%'B
5"!##!",! !"#B
!"#'
5#*##!
5)*/5>/2*>55*
*
• The XLB-3000 igniter module produces a 4 kV pulse during lamp ignition.
The igniter module should be placed as close as possible to the Xenon lamp
in order to keep the leads between the igniter and the Xenon lamp as short as
possible. No other wires should be in the vicinity of the igniter output wires
connecting to the Xenon lamp. The HV pulse produces transients that can
be destructive to low signal electronics.
• Please refer to Figure 3, XLB-3000 Igniter Outline Drawing, for information
regarding required clearances around the high voltage igniter coil.
9;5>
Because XLB-3000 units are designed for OEM applications, the user must
connect AC input power to the power supply chassis. Any input AC voltage
must be considered extremely dangerous, and as such, care must be taken to
connect AC input power to the unit.
13
*1Negative ignition is also available
!"#(
!
14
1. !"1
Figure 6 shows the interconnections between
the XLB-3000, the Igniter module and the Xenon lamp. Because the Igniter module
produces a high speed 4 kV pulse when igniting the Xenon lamp, it is important to
keep connections between the igniter module and the Xenon lamp as short as
possible to avoid I2R losses in the wire. Wire length of 30 cm or less is
recommended for reliable ignition!
2. 5"!!1
Connect the TR igniter sense connection
wire to the igniter module and the XLB-3000 main power supply chassis. The cable
for this connection has been provided. The location of the connections is shown in
Figure 6.
3. 5!1 Connect the user system to the 1 pin D-sub connector
shown in Figure . See Table 1 and Figure 4 for description of the XLB-3000
Interface and the associated simplified interface schematic.
4. )+!55!.!"),1 The unit
may be programmed for output current via Pin 7, the 5" function. But there are three
interface control signals which must be properly set before the output will deliver
current as programmed by 5"
B
a. 5*C1Pin 3, the 57Dmust be grounded via Pins 4, 9 or 1
in order for the output to deliver current.
b. *<*=: Pin 1, the *<*= signal is a V to 24V signal used
to turn the output section on.
c. 5"
1 Pin 7 accepts a 0-10V signal which results in output current as
shown in the table below. Note that even with 5"
3?4 set between 0V and
2V, when the lamp is turned on via *<*= the XLB-3000 will
deliver 20% of the maximum current rating of the unit. This is the
minimum current required to keep the lamp on. To deliver more than 20%
of the maximum rated current, 5"
(+) must be set higher than 2V.
5)**
Make sure when connecting interface that the current program
setting, 5"
3?4, is set no higher then the value required for Xenon
lamp operation. When AC power is applied and system is
, output current will rise to this program value
1
5"
3?4)!E 5#
0V 20% Iomax
2V 20% Iomax
4V 40% Iomax
6V 60% Iomax
8V 80% Iomax
10V 100% Iomax
%1#
. *!"
a. 5#),!1 Input power is shown below in Table 2.
Connect AC power connections to power supply input power terminals.
Refer to Figure for location of AC Input.
*8 5))*;
XLB-3000-XX-YY 200-240 VAC, 0/60 HZ, 18. A @ 208VAC
15#),F#!
• Ground wire shall be crimped to a # 8 ring-lug and connected to the
ground stud.
b. 5!" : Make sure 57, Pin 3, is connected to
GND via Interface pins 4, 9 or 1 .
c. .5#),1 Turn ON AC power. After a few seconds the
power supply fans will begin to run.
d. )"!"*###1
Program the XLB-3000 power supply
for the desired output current. A 0-10V signal applied to 5"
, Pin 7, will
program the XLB-3000 diode driver for 0 to maximum rated output
current.
e.*<*=1 Apply + V to +1 V to Lamp On/Off, Pin 1.
5)*))5**>85>5))*;
AC Input wires and Earth Ground wire should be at least #12 AWG; rated for at
least 300V and 10 oC.
5)*9**5))*;
XLB-3000 units are fused on both input lines. It does not matter which of the
two AC inputs are designated Line or Neutral.
16
6. !!"##1
a. #!Power supply output current can be monitored via pin
6, 5#
!. A 0-10V signal will represent the output current from 0 to
maximum rated output current.
b. 2"!Power supply output voltage can be monitored via pin
, 2#
!. A 0-10V signal will represent the output voltage from 0-
maximum output voltage.
c. *<*=#1Once the lamp has successfully ignited and at least
20% of the maximum rated current of the power supply is being delivered
to the lamp, the LAMP ON/OFF Status signal will go low.
EB 8*##!1
GB
+!!"1
XLB-3000 units have no serviceable parts. Do not attempt to repair or service this
unit in the field. Removing tamper seals from chassis will void warranty. For
further information, contact Lumina Power at 978-241-8260.
%(;/!8BDD$G'
)1HEG%&$G%( -1HEG%&$G%(%
,,,B#!,B
A#!,B
5)*))5**>85>
8*)*5*
The DC Output can be as high as 120 amps. It is recommended that the user
refer to the NEC for wire gauge guide lines for steady state and peak current
condition operation. Wire terminations should be sized accordingly and crimped
& soldered. Increased resistance due to poor connections will cause voltage
drops and I2R heating which could be dangerous or damaging to improperly
sized wires, wire insulation and/or terminations.
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