Explosion-proof Integrated LED Driver and Emergency Control Unit

Introduction

This is an integrated controller combining constant-current driving and emergency lighting functions, designed for explosion-proof LED luminaires. It utilizes a novel isolated circuit topology that integrates the LED driver with emergency backup power management. Under normal mains power conditions, the unit delivers a constant current to dual LED light sources while simultaneously charging an external 7.2V Ni-MH battery pack. In the event of a mains power failure, the controller automatically switches to emergency mode within 0.3 seconds, powering a single LED light source from the battery; the emergency duration depends on battery capacity—a standard 3Ah battery provides 90 minutes of emergency operation. The internal cavity is filled with explosion-proof quartz sand, and the input/output terminals are sealed with silicone potting compound. The circuit board and electronic components comply with explosion-proof standards, making the unit suitable for hazardous locations—such as those in the petroleum and chemical industries—where explosive gas mixtures may be present. It also features an output interface for a small indicator light to signal battery charge and discharge status.

Product Features

This power supply utilizes a novel isolated topology design that combines constant-current operation with emergency functionality. Key features include low noise, wide input voltage range, dual-channel output, energy efficiency, eco-friendliness, high power factor, high efficiency, input-output isolation, direct emergency drive for the light source, and rapid heat dissipation when integrated with the luminaire housing.

Product Performance

Open-Circuit Protection: If there is no load or an open circuit at the output, the unit immediately switches to a regulated voltage mode to prevent damage from excessive output voltage; it automatically resumes constant-current mode once the open-circuit condition is resolved.
Short-Circuit Protection: In the event of an output short circuit (positive and negative terminals touching), the unit automatically stops output to prevent permanent damage. Normal constant-current or regulated voltage operation resumes immediately after the short circuit is cleared.
Overload/Light-Load Protection: Designed for constant-current operation, the unit maintains a steady output current when the load is within the specified design range; it switches to overload or light-load protection mode if the load falls outside this range.
Battery Overcharge Protection: The controller employs voltage-limited constant-current charging; it switches to trickle charging when the voltage of an individual battery cell reaches 1.42V.
Battery Over-Discharge Protection: The controller automatically cuts off the output power when the voltage of an individual battery cell drops to a level within the 0.9V–1.1V range.
Battery Reverse Polarity Protection: The controller is protected against damage from reversed battery polarity; simply reconnect the battery with the correct polarity to restore operation.
Withstand Voltage: 1500V ±10% / 5mA / 1min / 50Hz between the main power input and the housing.
500V ±10% / 5mA / 1min / 50Hz between external live terminals and the housing.
Insulation Resistance: ≥50MΩ between the main power input and the housing.
≥20MΩ between external live terminals requiring insulation and the housing.
External LED Status Indicator: Red LED (Voltage: 1.9V–2.2V).
The indicator lights up to show charging status when normal AC mains power is supplied. In emergency mode (powered by the battery pack), the indicator light flashes steadily.
The indicator light turns off once the emergency mode ends.
Explosion-proof construction: The internal free space is filled with quartz sand, with partial silicone potting; the internal circuit board and electronic components comply with explosion-proof standards.

Usage Precautions and Installation Instructions

Usage Precautions:
1) The input voltage must be within the specified operating range of AC 100V–277V.
2) The product should be used within its rated ambient temperature range; ensure the power supply has adequate space and a suitable environment for heat dissipation.

Installation Instructions:
1) Connect the power supply to a mains power source with a protective earth (ground) connection to ensure operator safety.
2) Wire the unit strictly according to the terminal designations indicated on the housing label. Ensure connections are secure and verify that input/output lines are not swapped and battery polarity is not reversed.
3) Connect the power supply only after confirming that the load specifications fully match the power supply system specifications.

Abnormal Conditions and Troubleshooting

1) If the unit fails to light up or exhibits other issues after the initial electrical installation, disconnect the AC input. Check for correct wiring and inspect both the output and AC input terminals for poor contact.
2) If the LED lights up after installation but the output is abnormal, disconnect the AC input and check the DC output for overload or light-load conditions.

Model Information

Dimension Drawing

Unit（mm）

Dimensions (L × W × H)

Wiring Diagram