This document outlines the process for programming a Fulham WorkHorse Constant Current Programmable Driver, a device designed to power LED lighting applications with customizable current output. The programming is performed using a Fulham Hand Programmer, which allows users to set the desired current output for the driver.
Function Description
The Fulham WorkHorse Constant Current Programmable Driver is an electronic ballast specifically designed for LED lighting. Its primary function is to provide a stable, constant current to LEDs, which is crucial for their optimal performance, longevity, and consistent light output. Unlike traditional voltage-regulated power supplies, constant current drivers ensure that the current flowing through the LEDs remains constant, regardless of minor fluctuations in forward voltage due to temperature changes or manufacturing tolerances. This programmability allows for flexibility in LED fixture design and performance tuning, enabling users to adjust brightness, power consumption, and thermal management characteristics of their lighting systems.
The programming process involves connecting the hand programmer to the driver and using its interface to read the current factory setting, adjust it to a desired value, and then write that new setting to the driver's memory. This capability is particularly useful for manufacturers who need to configure drivers for various LED arrays or for installers who need to fine-tune existing installations.
Important Technical Specifications
The document provides a visual of the driver with some key specifications:
- Input Voltage: 120-277VAC. This indicates the driver is designed for universal input voltage, making it suitable for a wide range of electrical systems globally without requiring voltage converters.
- Input Current: 0.8A. This is the maximum current drawn by the driver from the AC mains.
- Input Power: 124W. This represents the maximum power consumed by the driver from the AC mains.
- Output Voltage: 10-57VDC. This is the range of DC voltage the driver can supply to the LED load. The actual output voltage will depend on the forward voltage characteristics of the connected LEDs.
- Output Current: 1050mA. This is the maximum programmable constant current output of the driver. The programming process allows users to set a specific current within the driver's operational range, up to this maximum. The example in the document shows programming to 1000mA.
- Output Power: 50W. This is the maximum power the driver can deliver to the LED load.
- Dimming: DALI (Digital Addressable Lighting Interface). This indicates the driver supports DALI for dimming control, allowing for advanced lighting control systems.
- Power Factor: >0.9. A high power factor indicates efficient use of electrical power, reducing reactive power and improving overall system efficiency.
- Efficiency: >85%. This specifies the percentage of input power that is converted into useful output power for the LEDs, with the remaining power dissipated as heat.
- Compliance: FCC Part 15B Compliant, EN55015, RoHS Compliant, CE, cAUs (UL/CSA equivalent). These certifications ensure the driver meets electromagnetic compatibility, safety, environmental, and quality standards for various markets.
- Operating Temperature: -45°C to 85°C. This wide operating temperature range highlights the driver's robustness and suitability for diverse environmental conditions.
- Sound Rating: A. This indicates a low noise level during operation.
- Type: TL 85/86C, Type HL. These classifications relate to specific safety and performance standards, likely concerning thermal performance and hazardous location suitability.
- Suitability: Suitable for LED luminaires, suitable for dry or damp locations. This specifies the environments where the driver can be safely installed.
The Fulham Hand Programmer, depicted in the manual, is a compact, handheld device with a digital display and several buttons (Mode, Read, Toggle, Program). It connects to the driver via a programming cable and can be powered by a third-party battery pack or a USB charging source.
Usage Features
The programming process is designed to be straightforward and user-friendly:
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Connection Identification: The manual emphasizes the importance of correctly identifying the connection method for programming. Drivers can have push-in connectors, bare wires, or output connectors.
- Push-In Connectors: For drivers with R-SET/PRG/NTC push-in connectors, the programming cable's forks are inserted directly. Polarity is crucial, and an error code (E-3) will display if incorrect. The polarity indicators on the cable should face up or down depending on the driver's specific polarity marking.
- Drivers with Leads (Wires): For drivers with bare leads (e.g., orange/yellow or purple/gray wires), a wire block adapter is used. The programming cable connects to the back of the adapter, and the driver's leads connect to quick-release connectors on the adapter, ensuring correct polarity (e.g., orange/purple to Red (+), yellow/gray to Black (-)).
- Drivers with Output Connectors: If the driver has a mating output harness plugged in, the R-SET/PRG/NTC wires from that harness can be used with the wire block adapter.
- Polarity: Consistent emphasis is placed on matching polarity to avoid errors and ensure successful programming.
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Hand Programmer Setup:
- The Hand Programmer is connected to a power source (battery pack or USB).
- The "Mode" button is used to toggle the programmer into "mA mode" (I-SET).
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Reading Current Setting:
- Pressing the "READ" button on the programmer displays the driver's current factory-set output current. This allows users to verify the existing configuration before making changes.
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Setting Desired Current:
- The "Toggle" button is used to adjust the displayed current value on the programmer to the desired output current for the driver (e.g., 1000mA).
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Programming the Driver:
- Pressing the "Program" button initiates the writing of the new current setting to the driver. The programmer's display will flash "PROG" to indicate the programming is in progress.
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Confirmation:
- After successful programming, the programmer will toggle between "OK" and the newly set current (e.g., "1000mA").
- Pressing "READ" again confirms the new setting stored in the driver.
- Important Note: If programming while the driver is powered, a power cycle (turning the driver off and then on again) is required for the new programmed current to take effect.
Maintenance Features
While the document does not explicitly detail maintenance features for the driver itself, the programming process implies certain aspects:
- Firmware Updates (Implied): The programmability of the driver suggests that its operational parameters can be updated or reconfigured, which is a form of maintenance for adapting to new requirements or correcting settings.
- Troubleshooting: The error code "E-3 (Error)" for incorrect polarity during programming provides a basic troubleshooting indicator, guiding users to correct connection issues.
- Durability and Reliability: The extensive technical specifications, including wide operating temperature range, high efficiency, and various compliance certifications (CE, RoHS, cAUs), indicate a robust design aimed at long-term reliability and minimal maintenance requirements under specified operating conditions.
- Environmental Compliance: RoHS compliance signifies that the driver is free from certain hazardous substances, contributing to easier disposal and reduced environmental impact at the end of its life cycle.
In summary, the Fulham WorkHorse Constant Current Programmable Driver is a versatile and robust component for LED lighting, offering precise current control through an intuitive programming interface. Its broad compatibility, high efficiency, and adherence to international standards make it a reliable choice for various lighting applications. The programming process, facilitated by the Fulham Hand Programmer, is designed for ease of use, allowing for quick and accurate configuration of the driver's output current.
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