Explosion-proof Standalone LED Emergency Control Unit

Introduction

This is a standalone emergency control unit designed for explosion-proof LED lighting fixtures. Utilizing an isolated circuit topology and digital control technology, it integrates with a standard LED driver and an emergency battery to form a dual-mode (normal/emergency) lighting system. Under normal power conditions, the LED light source is powered by the standard driver, while the emergency control unit charges the battery. Upon power failure, the unit automatically switches to emergency mode within 0.3 seconds; it boosts the battery voltage to the level required to operate the LEDs, thereby maintaining illumination. The unit features an output interface for a status indicator light to signal various operating states. Designed in strict accordance with explosion-proof standards, the internal circuitry and components are encapsulated in silicone potting compound, making the product suitable for environments with rigorous explosion-proof and emergency lighting requirements—such as petrochemical plants, gas stations, mines, tunnels, pharmaceutical facilities, and workshops with combustible dust.

Product Features

This is a standalone emergency control unit developed by our company specifically for explosion-proof LED luminaires. With the continuous emergence of new materials, technologies, and manufacturing processes in recent years, a wide variety of LED drivers have been produced, marking a critical period of innovation and upgrading in the lighting industry. The 1106001 series emergency control unit utilizes a state-of-the-art isolated topology circuit design featuring comprehensive circuitry and digital control. Key characteristics include low noise, energy efficiency, environmental friendliness, high efficiency, input-output isolation, direct emergency driving of the light source, integration with the luminaire housing, and rapid heat dissipation.

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 caused by excessive output voltage; it automatically resumes constant-current operation once the open-circuit condition is resolved.
Short-Circuit Protection: In the event of an output short circuit (positive and negative terminals connecting), the unit automatically halts 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. If the load falls outside this range, the unit enters a protection mode: 1) If the output voltage is too low, the driver enters a cycle of frequent startup and shutdown, causing the LEDs to flicker; 2) If the output voltage is too high, the unit switches to a constant-voltage protection mode, resulting in reduced LED brightness as the current fails to reach the default value.
Battery Overcharge Protection: The controller employs a voltage-limited, constant-current charging method; it switches to trickle charging once 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. Dielectric Strength: 1500V ±10% / 5mA / 1min / 50Hz between main power input and enclosure
500V ±10% / 5mA / 1min / 50Hz between external live terminals and enclosure
Insulation Resistance: ≥50MΩ between main power input and enclosure
≥20MΩ between external live terminals (requiring insulation) and enclosure
Indicator Functions: Supports external green, red, and yellow LEDs; green light steady on for mains power status; red light on for battery charging; red light off for battery trickle charging; yellow light on for battery fault

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