This invention relates generally to lighting systems, and more specifically to electronic ballast protection.
Gas discharge lamps, such as fluorescent lamps and high intensity discharge (HID) lamps, require a ballast to limit the current to the lamp. Electronic ballasts have become increasingly popular due to their many advantages. Electronic ballasts provide greater efficiency—as much as 15% to 20% over magnetic ballast systems. Electronic ballasts produce less heat, reducing building cooling loads, and operate more quietly, without “hum.” In addition, electronic ballasts offer more design and control flexibility.
One particular challenge is to protect the electronic ballast during installation and startup. The electronic ballast includes electronic components which can be damaged by high currents if the electronic ballast is miswired during installation. Other electronic ballast components fail over time due to temperature and thermal stresses from igniting the lamp.
Presently, correct wiring of the electronic ballasts depends on the skill and care of the installer. The location of the label on the ballast housing and the color coding of the wires are the only means to determine which wires should be connected to the mains voltage and which wires should be connected to the lamp. Miswiring the electronic ballast, e.g., switching the mains voltage connection and the lamp connection, will damage the electronic ballast when mains voltage is applied. If the mains voltage is applied to the ballast output, the DC bus is energized and the low voltage power supply provides power to the control circuit. The control circuit switches the MOSFETs, shorting the mains voltage through the diode of a MOSFET which is off, the MOSFET which is on, and the filter circuit. The short circuit continues until the MOSFET is damaged and opens, or an external circuit breaker opens. The MOSFET damage renders the electronic ballast inoperable.
Electronic ballast components are subject to high temperatures and thermal stresses when igniting the lamp. During lamp startup, the resonant circuit provides a high ignition voltage on the ballast output. The ignition voltage is a sustained ignition pulse containing high frequency voltage components. The resonant current, which flows through the resonant inductor and the resonant capacitor of the resonant ignitor, is high and energy is dissipated as heat in the resonant inductor. The higher the ignition voltage and longer the ignition voltage is applied, the more heat builds up in the resonant inductor and raises inductor temperature. When the core temperature of the inductor coil exceeds its rated limits, core breakdown occurs and renders the electronic ballast inoperable.
Another problem occurs with electronic ballasts using sweeping startups. In some electronic ballasts, the inverter frequency sweeps downward as the ignition voltage sweeps upward to overcome the effect of cable capacitance and reach the resonant frequency producing the required peak voltage. This further degrades the inductor by allowing heat buildup during the approach to the resonant frequency. In addition, a slow ignition voltage sweep reduces the likelihood of successful ignition, requiring repeated startup attempts.
It would be desirable to have electronic ballast protection that overcomes the above disadvantages.
One aspect of the present invention provides a method of electronic ballast protection including providing an electronic ballast having an AC/DC converter with an electronic ballast input and a mains voltage connection connectable to a mains voltage, an inverter operably connected to the AC/DC converter and having an electronic ballast output connectable to a lamp, a control circuit controlling the inverter, and a low voltage power supply providing low voltage power to the control circuit; supplying power to the low voltage power supply from the electronic ballast input when the mains voltage connection is wired to mains voltage; and disconnecting the power to the low voltage power supply when the electronic ballast output is wired to the mains voltage.
Another aspect of the present invention provides a system of electronic ballast protection including an electronic ballast having an AC/DC converter with an electronic ballast input and a mains voltage connection connectable to a mains voltage, an inverter operably connected to the AC/DC converter and having an electronic ballast output connectable to a lamp, a control circuit controlling the inverter, and a low voltage power supply providing low voltage power to the control circuit; means for supplying power to the low voltage power supply from the electronic ballast input when the mains voltage connection is wired to the mains voltage; and means for disconnecting the power to the low voltage power supply when the electronic ballast output is wired to the mains voltage.
Yet another aspect of the present invention provides an electronic ballast with ballast protection including an AC/DC converter receiving mains voltage at a mains voltage connection and generating DC bus voltage from the mains voltage, the AC/DC converter having an electronic ballast input; an inverter receiving the DC bus voltage and generating output power at an electronic ballast output connectable to a lamp; a control circuit controlling the inverter; and a connection sensor operably connected to a location selected from the group consisting of the electronic ballast input and the electronic ballast output, wherein the connection sensor provides a connection sensor signal to the control circuit, and the control circuit shuts down the inverter when the connection sensor signal is not an expected connection sensor signal, lack of the expected connection sensor signal resulting from a miswire selected from the group consisting of connection of the mains voltage with the electronic ballast output and connection of the lamp with the mains voltage connection.
Yet another aspect of the present invention provides a method of electronic ballast protection including providing an electronic ballast having an electronic ballast input connectable to a mains voltage and an electronic ballast output connectable to a lamp, monitoring an electronic ballast parameter at a location selected from the group consisting of the electronic ballast input and the electronic ballast output, and shutting down the electronic ballast when the electronic ballast parameter is not an expected electronic ballast parameter, lack of the expected connection sensor signal resulting from a miswire selected from the group consisting of connection of the mains voltage with the electronic ballast output and connection of the lamp with the electronic ballast input.
Yet another aspect of the present invention provides a system of electronic ballast protection including an electronic ballast having an electronic ballast input connectable to a mains voltage and an electronic ballast output connectable to a lamp, means for monitoring an electronic ballast parameter at a location selected from the group consisting of the electronic ballast input and the electronic ballast output, and means for shutting down the electronic ballast when the electronic ballast parameter is not an expected electronic ballast parameter, lack of the expected connection sensor signal resulting from a miswire selected from the group consisting of connection of the mains voltage with the electronic ballast output and connection of the lamp with the electronic ballast input.
Yet another aspect of the present invention provides a method of electronic ballast protection including providing an electronic ballast having an electronic ballast output, and generating an ignition voltage at the electronic ballast output during lamp startup, the ignition voltage comprising a series of ignition voltage pulses, wherein the series of ignition voltage pulses are timed so as to limit component temperature in the electronic ballast.
Yet another aspect of the present invention provides a system of electronic ballast protection comprising an-electronic ballast having an electronic ballast output, and means for generating an ignition voltage at the electronic ballast output during lamp startup, the ignition voltage comprising a series of ignition voltage pulses, wherein the series of ignition voltage pulses are timed so as to limit component temperature in the electronic ballast.
The foregoing and other features and advantages of the invention will become further apparent from the following detailed description of the presently preferred embodiment, read in conjunction with the accompanying drawings. The detailed description and drawings are merely illustrative of the invention rather than limiting, the scope of the invention being defined by the appended claims and equivalents thereof.
When the electronic ballast 200 is correctly wired, with the mains voltage connection 103 wired to the mains voltage 102, the low voltage power supply 114 is powered from the electronic ballast input. Should the electronic ballast 200 be incorrectly wired during installation, such as by connecting the electronic ballast output 125 to the mains voltage 102, the low voltage power supply 114 will not receive power from the mains voltage 102, the control circuit 116 will remain deenergized, and the inverter 120 will not switch. This prevents short circuiting the mains voltage 102 through the MOSFETs S1, S2, S3, S4, and filter circuit 128 of the inverter 120, preventing damage to the electronic ballast 200.
In one embodiment, an input sensor 302 as a connection sensor is connected to the electronic ballast input. The electronic ballast input is defined as any location in the electronic ballast 200 operably connected to the mains voltage 102 before the DC bus 112. In the embodiment illustrated, the input sensor 302 is connected to the electronic ballast input at the mains voltage connection 103. In alternative embodiments, the input sensor 302 is connected to the EMI filter-diode bridge connection 107 or the diode bridge-DC/DC converter connection 109. The input sensor 302 can be a voltage sensor or a current sensor, as desired. The input sensor 302 provides an input sensor signal 304 as a connection sensor signal to the control circuit 116.
When power is applied to the electronic ballast 300, the input sensor 302 monitors the electronic ballast input for an electronic ballast parameter, such as input voltage or input current, and provides the input sensor signal 304 to the control circuit 116. The control circuit 116 determines whether the input sensor signal 304 is the expected connection sensor signal. The expected connection sensor signal is signal present at startup, indicating voltage or current on the electronic ballast input. When the electronic ballast 300 has been properly wired, the input sensor signal 304 indicates the mains voltage 102 supplying power and the connection sensor signal is signal present. The electronic ballast operation is allowed to continue. When the electronic ballast 300 has been miswired, such as wiring the mains voltage connection 103 to the lamp 124, the input sensor signal 304 indicates no power. Because the expected connection sensor signal is signal present and the connection sensor signal indicates no signal present, the control circuit 116 determines that miswiring has occurred and shuts down the inverter 120 to shut down the electronic ballast 300. When the electronic ballast parameter is not the expected electronic ballast parameter, the electronic ballast is shut down to prevent damage to the electronic ballast components.
In an alternative embodiment, an output sensor 306 as a connection sensor is connected to the electronic ballast output 125. The output sensor 306 can be a voltage sensor or a current sensor, as desired. The output sensor 306 provides an output sensor signal 308 as a connection sensor signal to the control circuit 116.
When power is applied to the electronic ballast 300, the output sensor 306 monitors the electronic ballast output 125 for an electronic ballast parameter, such as output voltage or output current, and provides the output sensor signal 308 to the control circuit 116. The control circuit 116 determines whether the output sensor signal 308 is the expected connection sensor signal. The expected connection sensor signal is no signal present, indicating no voltage or current on the electronic ballast output 125 at startup. When the electronic ballast 300 has been properly wired, the output sensor signal 308 indicates no power on the electronic ballast output 125 at startup and the connection sensor signal is no signal present. The electronic ballast operation is allowed to continue.
When the electronic ballast 300 has been miswired, such as wiring the electronic ballast output 125 to the mains voltage 102, the output sensor signal 308 indicates power. Because the expected connection sensor signal is no signal present and the connection sensor signal indicates signal present, the control circuit 116 determines that miswiring has occurred and shuts down the inverter 120 to shut down the electronic ballast 300. When the electronic ballast parameter is not the expected electronic ballast parameter, the electronic ballast is shut down to prevent damage to the electronic ballast components.
In another alternative embodiment, an input sensor 302 as a first connection sensor is connected to the electronic ballast input and an output sensor 306 as a second connection sensor is connected to the electronic ballast output 125. The input sensor 302 provides an input sensor signal 304 as a first connection sensor signal to the control circuit 116 and the output sensor 306 provides an output sensor signal 308 as a second connection sensor signal to the control circuit 116. The control circuit 116 shuts down the inverter 120 to shut down the electronic ballast 300 when the input sensor signal 304 or the output sensor signal 308 is not in its expected state at startup. This provides additional assurance of proper wiring installation as both the input sensor signal 304 and the output sensor signal 308 must be in their expected state before electronic ballast operation is allowed.
In one embodiment, a temperature sensor 402 is provided to monitor the temperature of a ballast component, such as the resonant inductor LR, and provide a component temperature signal 404 to the control circuit 116. The component temperature can be monitored at the ballast component or on the circuit board near the ballast component. The control circuit 116 can adjust the operation of the inverter 120 to adjust timing of the series of ignition voltage pulses on the electronic ballast output 125 in response to the component temperature. Timing adjustment is discussed further in conjunction with the description of
In an alternative embodiment, a voltage sensor 406 is provided to monitor the ignition voltage at the electronic ballast output 125 during startup and to generate an ignition voltage signal 408 provided to the control circuit 116. On the initial startup after ballast installation, the control circuit 116 stores an initial output frequency corresponding to a required ignition voltage. The required ignition voltage is a high voltage which should occur at the fundamental frequency of the resonant circuit 126, or at a higher order harmonic frequency, such as the third harmonic frequency, but which actually varies from the fundamental or higher order harmonic frequency due to component tolerances and cable capacitance. The initial output frequency is determined for the installed electronic ballast, so the uncertainties are accounted for. Once the initial output frequency is known, the ignition voltage for subsequent startups as set by the control circuit 116 control of the inverter 120 begins at the initial output frequency plus a predetermined percent, such as 10 percent of the initial output frequency. The control circuit 116 sweeps the output frequency downward from the initial output frequency plus the predetermined percent to start the lamp.
In another alternative embodiment, the voltage sensor 406 is used to provide feedback to the control circuit 116. The voltage sensor 406 monitors ignition voltage as the output frequency sweeping downward from a beginning output frequency, such as a predetermined percent of the output frequency at which the required output voltage is expected to occur. The downward of the output frequency is halted when the ignition voltage reaches the required ignition voltage. The output frequency is adjusted by the control circuit 116 in response to the ignition voltage indicated by the ignition voltage signal 408 to maintain the ignition voltage at the required ignition voltage. The limited sweep from use of the voltage sensor 406 protects the ballast components from excessive heating of longer sweeps and repeated cycling from failed startup attempts.
In yet another alternative embodiment, the voltage sensor 406 is used to provide ignition indication to the control circuit 116. A lamp current sensor (not shown) monitors lamp current to the lamp 124 and provides an indication of lamp current to the control circuit 116. The control circuit 116 detects lamp breakdown indicating successful ignition based on the ignition voltage and the lamp current. The electronic ballast 400 continues to generate a high frequency current, typically at a frequency above 20 kHz, at the electronic ballast output 125 for a first period after the lamp breakdown to assure successful ignition. The first period can be as long as 500 milliseconds and is typically 50 milliseconds. After the first period, the electronic ballast 400 generates a low frequency current, typically at a frequency below 500 Hz, at the electronic ballast output 125. In one embodiment, the electronic ballast 400 generates the ignition voltage at the electronic ballast output 125 when lamp voltage and the lamp current indicate the lamp has extinguished within a second period, such as 10 seconds after the lamp breakdown. This restarts the ignition process when a previous start fails.
Examples of ranges for the timing of the series of ignition voltage pulses are 0.01 to 3.00 seconds for the duration of each of the ignition voltage pulses 506, with a typical value of 0.90 seconds; 0.01 to 30 seconds for the duration of each of the voltage spaces 508, with a typical value of 6 seconds; 0.01 to 100 seconds for the duration of the pulse portion 502, with a typical value of 20 seconds; and 30 and 300 seconds for the duration of the rest portion 504, with a typical value of 300 seconds. The duration of each of the ignition voltage pulses 506 and each of the voltage spaces 508 is selected to prevent component temperature, such as inductor core temperature, from exceeding the component temperature breakdown limit. The duration of rest portion is selected to allow the electronic ballast component to cool down. Those skilled in the art will appreciate that the timing for a particular ballast depends on the characteristics of the particular ballast design, such as electronic ballast components used, power output, housing ventilation, heat transfer properties, insulation, and anticipated environment. The timing can be held constant from one series to the next or can be changed as desired.
The ignition voltage pulse parameters, i.e., the durations of the ignition voltage pulses, the voltage spaces, the pulse portion, and the rest portion, can be collected as values sets to be used for timing the series of ignition voltage pulses in particular situations. For example, when the component temperature is in a temperature band away from the component temperature breakdown limit, the timing of the series of ignition voltage pulses can be a first values set at the lower end of the range for the ignition voltage pulse parameters. When the component temperature is in a temperature band near the component temperature breakdown limit, the timing of the series of ignition voltage pulses can be a second values set at the upper end of the range for the ignition voltage pulse parameters. When the component temperature is in a temperature band above the component temperature breakdown limit, the ignition voltage can be shut down to protect the ballast component.
The series of ignition voltage pulses are timed to limit component temperature in the electronic ballast. In one embodiment, the timing is calculated for a particular electronic ballast design and the timing is maintained the same for the service life of the ballast. In an alternative embodiment, the timing is adjusted dynamically in response to an electronic ballast measurement, such as component temperature, and the timing can change during a given startup. In another alternative embodiment, the timing can be adjusted from one lamp startup to another, based on performance during the previous startup or a previous series of startups.
While the embodiments of the invention disclosed herein are presently considered to be preferred, various changes and modifications can be made without departing from the scope of the invention. The scope of the invention is indicated in the appended claims, and all changes that come within the meaning and range of equivalents are intended to be embraced therein.
This application claims the benefit of U.S. provisional application Ser. No. 60/602,895, filed Aug. 19, 2004 and application Ser. No. 60/586,947, filed Jul. 9, 2004 which the entire subject matter is incorporated herein by reference.
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