Tridonic 89800638 EMconverterLED PRO 204 MH/LiFePO4 250V – DALI 2 Certified

89800638 Common Data

Ordering data EM converterLED PRO 204 MH/LiFePO4 250V 89800638

89800638 Technical data

Rated supply voltage 220 – 240 V
AC voltage range 198 – 264 V
Mains frequency 50 / 60 Hz
Forward voltage range LED module 50 – 250 V
Output current Refer to data sheet
Starting time < 0.5 s from detection of emergency event
Overvoltage protection 320 V (for 48 h)
U-OUT (including open- / short-circuit and double load) 300 V
Max. open circuit voltage 300 V
Ambient temperature ta -25 … +55 °C
Max. casing temperature tc 80 °C

Mains voltage changeover threshold According to EN 60598-2-22
Mains surge capability (between L – N) 1 kV
Mains surge capability (between L/N – PE) 2 kV
Type of protection IP20
Rest mode max. number of emergency units 100
Rest mode max. wiring distance 1,000 m
Functional test Weekly 5s test
Duration test Yearly 1 h / 2 h / 3 h test
Lifetime up to 100,000 h
Dimensions L x W x H 179 x 30 x 21 mm

89800638 Standards

• EN 61347-1
• EN 61347-2-13
• EN 61347-2-7
• EN 55015
• EN 61000-3-2
• EN 61000-3-3
• EN 61547
• EN 60068-2-64
• EN 60068-2-29
• EN 60068-2-30
• EN 62384
• DALI standard EN 62386-202
• according to EN 50172
• according to EN 60598-2-22
• according to EN 62034

Glow-wire test

According to EN 61347-1 with increased temperature of 850 °C passed.

Insulation and electric strength testing of luminaires

Electronic LED-Drivers can be damaged by high voltage. This has to be considered during the routine testing of the luminaires in production.

According to IEC 60598-1 Annex Q (informative only!) or ENEC 303-Annex A, each luminaire should be submitted to an insulation test with 500VDC for 1 second. This test voltage should be connected between the interconnected phase and neutral terminals and the earth terminal. The insulation resistance must be at least 2 MΩ.

As an alternative, IEC 60598-1 Annex Q describes a test of the electrical strength with 1,500VAC (or 1,414 x 1,500VDC). To avoid damage to the electronic devices this test must not be conducted.

Thermal details and lifetime

Average lifetime 50,000 hours under rated conditions with a failure rate of less than 10 %. Average failure rate of 0.2 % per 1000 operating hours.

The emergency lighting LED driver is designed for a lifetime stated above under reference conditions and with a failure probability of less than 10 %.

The relation of tc to ta temperature depends also on the luminaire design.

If the measured tc temperature is approx. 5 K below tc max., ta temperature should be checked and eventually critical components (e.g. ELCAP)
measured. Detailed information on request.

89800638 Installation / Wiring

One or more LED modules with a total forward voltage of 50 to 250 V can be connected to the 89800638. These LED module(s), marked with “Emergency” are operated in emergency mode from the associated battery. In normal mains mode all LED modules are operated by the mains LED driver.

89800638 Wiring type and cross section

Solid wire with a cross section of 0.5 – 1.5 mm². Strip 8 – 9 mm of insulation from the cables to ensure perfect operation of terminals.

Wiring: LED module/LED driver/supply

Loose wiring

89800638 Wiring guidelines

• The output to the LED is DC but has high frequency content, which should be considered for good EMC compliance.
• Separate LED leads from the mains and DALI connections and wiring for good EMC performance.
• Maximum lead length on the LED terminals is 3 m. For a good EMC performance keep the LED wiring as short as possible.

• Route the secondary wires (LED module) in parallel to ensure good EMC performance.
• Maximum lead length for the Test switch and Indicator LED connection is 1 m. Separate the test switch and Indicator LED wiring from the LED leads to prevent noise coupling.
• Battery leads are specified with 0.5 mm cross section and a length of 0.8 m
• DALI terminals are mains proof.
• Protect the wiring against short circuits to earth (sharp edged metal parts, metal cable clips, louver, etc.) to avoid the damage of the control gear.

To ensure that a luminaire containing LED emergency units complies with EN 55015 for radio frequency conducted interference in both normal and emergency mode it is essential to follow good practice in the wiring layout.

Within the luminaire route the switched and unswitched 50Hz supply wiring as short as possible and keep it as far away as possible from the LED leads.

Through wiring may affect the EMC performance of the luminaire.

Do not exceed the max. length of LED leads to the LED module. Note that the length of the 89800638 leads to the LED module is added to the length of the leads from the LED driver to the 89800638 module when considering the max. permitted lead length of the LED driver.

Use of different phases

The use of different phases for switched line and unswitched line is allowed.

When using different phases, the unswitched line must fail if the switched line fails. This is required to assure correct switching into emergency mode. It
can be realised with a relay.

89800638 Mechanical values

89800638 Housing properties

• Casing manufactured from polycarbonate.
• Type of protection: IP20
• Max. torque at the mounting screws: 0.8 Nm

Mechanical data accessories

LED status indicator
• Bi-colour
• Mounting hole 6.5 mm diameter, 1 – 1.6 mm thickness
• Lead length 0.3 m / 1.0 m
• Insulation rating: 90 °C
• Plug connection

Test switch

• Mounting hole 7.0 mm diameter
• Lead length 0.55 m
• Plug connection

Battery connection for the 89800638

• Plug connection 0.3 m
• Extension 0.5 m

LED driver compatibility

The 89800638 emergency unit use 3 pole technology and is compatible with most LED drivers on the market, however it is important to check that the rating of the LED driver does not exceed the values specified below:

• The max. allowed output current rating of the associated LED driver is 2 A eff (current rating of the terminals of EM converterLED) and 2.4 A peak (current rating of switching relays of EM converterLED)

• The max. allowed inrush current rating of the associated LED driver is 60 A peak for 1 ms or 84 A for 255 μs (inrush current rating of switching relay of EM converterLED)

• The max. allowed output voltage (U-OUT) of the associated LED driver applied to the 89800637 output is 450 V (voltage withstand between adjacent contact of the single switching relay of the 89800638)

• The max. allowed LED load of the associated LED driver is 150 W in operation. The load must be an LED module.

Check compatibility with the carried out function test (duration at least 5 seconds) individually for each device.

Software / Programming / Interfaces

Software / programming

With appropriate software and interface different functions can be activated and various parameters can be configured in the LED driver.
The Driver supports the following software and interfaces:
Software / hardware for configuration:
• companionSUITE (deviceGENERATOR, deviceCONFIGURATOR, deviceANALYSER)
• masterCONFIGURATOR
Interfaces for data transfer:
• Control input DALI

Control input DALI

The control input is non-polar for digital control signals (DALI).
The control signal is not SELV. The control cable has to be installed in accordance to the requirements of low voltage installations.
Digital control with:
• DALI signal: 16 bit

89800638 Functions

OEM Identification

The OEM (Original Equipment Manufacturer) can set his own identification number.

OEM GTIN

The Original Equipment Manufacturer (OEM) can set his own Global Trade Item Number (GTIN).

Label information

In production, an individual label can be printed out for each device.

For this there are different default values (Batch No., Production Date, …) available.

In addition, you can use these two text input fields to insert your own luminaire information and print it out.
• Article number (48 characters)
• Description (6 x 48 characters)

This information is not stored on the device, it is only used for the label print function in the deviceCONFIGURATOR.

Prolong time

Prolong time can be set by the DALI controller.
Here you can set how long the emergency operation will be maintained after power recovery.

The module exits the PROLONG mode as soon as the cut-off threshold of the battery voltage has been reached (total discharge protection), that is when the total operating time has been exceeded.

The default prolong time is set as 0 minutes as specified within the DALI standard.

Indicator LED will stay off for the duration of the prolong time.

Autotest

Functional test

The time of day and frequency of the 5 seconds function test can be set by the DALI controller. The default setting is a 5 seconds test on a weekly basis.

Duration test

The time of day and frequency of the duration test can be set by the DALI controller. The default setting is a duration test conducted every 52 weeks.

For 2 h operation:
The first commissioning duration test has a time of 120 minutes, subsequent through life tests are conducted for 90 minutes. When the battery is changed or disconnected and re-connected the unit will next conduct a 120 minute test.

Test window

The test window sets the maximum time between the scheduled start time or test request via DALI and the actual execution of the test. If the test cannot be executed in the test window, the TEST EXECUTION TIMEOUT bit in the FAILURE STATUS is set.

Duration link selection

Emergency lighting LED driver supplied with duration link in 3 hours position (position A).

The position of the link will only be read on first power up. If it is changed afterwards both the battery and mains supply must be disconnected for 10 seconds to enable the 89800638 to read the new link position on reconnection of the battery and mains. It will lead to a false battery failure indication if the link is changed after installation without this reset.

Testing

DALI Control
A DALI command from a suitable control unit can be used to initiate function and duration tests at individually selected times. Status flags are set for report back and data logging of results.

When a DALI bus has not been connected or when a DALI bus is connected but the DALI default DELAY and INTERVAL times have not been re-set by sending appropriate DALI commands, then the 89800638 will conduct self-tests in accordance with the default times set within the EEPROM.

These default times are factory pre-set, in accordance with the DALI standard EN 62386-202, to conduct an automatic function test every 7 days and a duration test every 52 weeks. Since the DELAY time is factory pre-set to Zero, all units are tested at the same time. Test times can be changed with a command over the DALI bus.

The DELAY and INTERVAL time values must be re-set when the emergency system test times are to be scheduled by a DALI control and monitoring system.

Note that once the default values have been set to Zero, tests will only be conducted following a command from the control system. If the DALI bus is disconnected the 89800627 does not revert to self-testing mode.

Note: If the battery is connected the DALI communication is only possible after power reset.

Addressing

The 89800638 includes the EZ easy addressing system which allows addressing and identification by using the bi-colour LED in conjunction with the EM PRO addressing tool.

Binary address codes given by the LED can be simply converted to the DALI addresses 0 to 63. For single handed addressing using this method it is necessary to send a broadcast ident command every 3 to 9 seconds. During this command the LEDs will be switched off and the indication LED will flash the 6 bit binary address preceded
by a 3 second start indication period.

Commissioning

After installation of the luminaire and initial connection of the mains and battery supply to the 89800638 the device starts with the 20 hours initial charge followed by a 4 hours trickle charge for NiCd/NiMH batteries or with a 24 hours initial charge for LiFePO4 batteries.

Afterwards the device conducts a commissioning test for the full duration. The 20 hours recharge for NiCd/NiMH batteries or 24 hours recharge for LiFePO4 batteries occurs also with the connection of a new battery. The following automatic commissioning duration test only takes place when a battery is replaced and fully charged and the interval time is not set to zero. In case the interval time is set to zero the device expects the DALI system to request the testing.

Rest Mode / Inhibit Mode

Emergency operation is automatically started when the mains supply is switched off. If the Rest Mode is activated, the discharging of the battery will be minimized by switching off the LED output. If the Inhibit Mode has been activated before the mains supply is switched off, Rest Mode will be automatically switched on if the mains supply is switched off within 15 minutes.
Rest Mode and Inhibit Mode can be initiated by the DALI controller. The REST command has to be sent after the mains supply has been disconnected and whilst the 89800638 is in emergency operation.

The INHIBIT command has to be sent while the 89800638 is supplied by mains. After a mains reset the 89800638 exits the Rest Mode. Rest Mode and Inhibit Mode can both be disabled by sending the RE-LIGHT/ RESET INHIBIT command.

Rest Mode / Inhibit Mode are not supported from 89800637 in case of combination with a 1-cell LiFePO4 battery and 2-cell NiMH battery.

Test switch

An optional test switch can be wired to each 89800638.
This can be used to to:
• Initiate a 5 seconds function test: press 200 ms < T < 1s
• Execute function test as long as switch pressed: press > 1s
• Reset selftest timer (adjust local timing): press > 10 s

Timer reset functionality

The timer for function and duration test can be set to a particular time of the day by either pressing the test switch for longer than 10 seconds or cycling the unswitched line supply 5 times within 1 minute. The timer adjustment will enable the test start time to be defined manually at time in day when the timer was reset. It will also disable the adaptive test algorithm thereby
forcing the unit to perform the test at the same time rather than it being defined by the adaptive algorithm. This function will only work provided the interval time is greater than zero (automatic test mode enabled).

The factory programmed delay offset (1 – 28 days) will be loaded after the reset into the delay timer for the function and duration test in order to randomize the tests
between adjacent units.

BlackBox data recording

Parameters providing information about the application and use are stored in the 89800638. The parameters stored provide information on the mains, battery, LED output and emergency operation. The BlackBox can be read out with the masterCONFIGURATOR and deviceANALYSER.

DALI Controller

DALI controllers and hardware/software solutions are available from Tridonic. Please refer to the Lighting controls section.

Safety

Note: LiFeGuard ensures safe and reliable battery operation by offering a comprehensive three-layered safety system. It addresses the cell, battery pack and emergency driver.

Deep discharge protection

When the battery remains connected without charging for a long period of time after the battery cut off of the driver the battery voltage can still drop. To make sure the cells are not damaged by this voltage drop, the battery protection prevents the battery from further discharge below 2.0 V.

Overcharge protection

If in case of an error or the use of a wrong driver the battery gets overcharged the battery protection will disconnect the battery from the driver at a voltage of 3.9 V. A discharge of the battery is still possible after the protection circuit was triggered to guarantee emergency operation.

Short-circuit protection

In case of a short circuit the battery protection opens the connection to the driver and the output is therefore free of voltage. The output will be reactivated again when the short circuit is removed.

Overtemperature protection

The battery is protected against temporary thermal overheating. If the temperature limit is exceeded the further charging of the battery is no longer possible. The temperature protection is activated below approx. 0 °C and above approx. +60 °C. The discharging of the battery is still possible to guarantee emergency operation. The charging is automatically activated when the temperature is within the range of 0 to 60°C again.

Battery has built in thermal sensor for safe charging. Mount battery away from heat source. Positioning of the thermal sensor see battery data sheet.

Storage, installation and commissioning

Relevant information about storage conditions, installation and commissioning are provided in the battery datasheets.

Activating NiMH batteries:

In order to activate new batteries, 2-3 full charge-discharge cycles could be needed. This activating process is defined by charging (24 h) and discharging (1/2/3 h) of the batteries. If the first duration test fails, please repeat the test after a 24 hour charging period.

Miscellaneous

Maximum number of switching cycles 89800638 are tested with 50,000 mains switching cycles of the associated LED driver.

Battery replacement

After a battery replacement and a subsequent full charge cycle (24 h) a duration test is mandatory to prove that with the new battery the rated duration is achieved.

FELV control terminals

FELV control terminals marked „Risk of electric shock“ are not safe to touch. Insulate circuits connected to any FELV control terminal for the Low Voltage supply voltage of the control gear. Protect terminals connected to the FELV circuit against accidental contact.

BlackBox data recording

Several parameters in respect to the application and use of the product are stored in the 89800637. The parameters provide information about
the mains, battery, LED output and emergency operation.

The BlackBox can be read out with the masterCONFIGURATOR and deviceANALYSER. In order to allow a safe detection of a battery replacement through the “Black Box data recording” follow the below described process.

Battery replacement
1. Disconnect mains
2. Disconnect battery
3. Reconnect and disconnect mains while no battery is not connected1
4. Connect new battery
5. Connect mains2

1 Battery fault is safely recorded by the 89800638
2 Connection of new battery is recorded by the 89800638

Mains-connected transformers

The 89800638 does not contain mains-connected windings of transformers.

DALI emergency modules (type 1) are intelligent components for emergency lighting, enabling automatic, centralized testing, monitoring, and reporting of battery and lamp status over a two-way DALI network. They ensure compliance with safety standards (e.g., BS, ICEL) by automatically conducting, logging, and reporting monthly function and annual duration tests, eliminating manual testing. These modules, which often include Lithium Iron Phosphate (LiFePO4) batteries and integrate into existing DALI lighting, allow for staggered testing to avoid disrupting building users.

Key Features and Benefits

Automatic Testing & Reporting: Eliminates manual checks by automatically scheduling and logging emergency function and duration tests.

Centralized Monitoring: Real-time, two-way communication enables monitoring of battery capacity, lamp failure, and overall status via a PC or touch screen.

Reduced Maintenance Costs: Automated, accurate data reduces labour costs and provides reliable reporting for regulatory compliance.

Intelligent Features: Many modules, such as the LDM DALI-2 NFC, feature NFC for diagnostics, battery management, and automatic adaptation to LED module forward voltage.

Compliance: Fully compliant with IEC standards for DALI emergency lighting.

Technical Specifications

Power & Output: Typically supports 3-hour emergency duration, with around 3W power consumption and ~300 lumens output, though specifications vary by module.

Compatibility: Designed for LED luminaires with a forward voltage (\(V_{f}\)) typically between 6V and 55V.

Battery Technology: Commonly uses high-temperature Lithium Iron Phosphate (LiFePO4) or Nickel Metal Hydride (NiMH) batteries.

Network Limits: A DALI bus can support up to 100 or more devices, with recommended max cable lengths often around 1000m, depending on the system design.

Standalone Functionality: Many DALI modules default to a standalone AutoTest mode if not connected to a active DALI bus.

How They Work

Power Failure: Upon mains failure, the module’s 2-pole relay disconnects the LED from the main driver and switches it to the emergency battery pack.

Monitoring: The module continuously monitors battery charging, voltage, and temperature to ensure it is ready for an emergency.

Data Reporting: Through the DALI network, the module reports to a central controller, identifying faults in specific luminaires.

Integration

DALI emergency modules run on the same network as standard DALI control systems, allowing for seamless integration into smart building infrastructures. They can be managed by specific DALI-2 display units for scheduling and logging, with data exportable for reporting purposes.

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