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August 1997
Application Brief 42022 ML4833 220V Non-Dimming Ballast Design
GENERAL DESCRIPTION
This Application Brief exists as a supplement to Application Note 63. When used with Application Note 63, this document contains all the necessary information to convert an ML4833 Evaluation Board into a low-cost, non-dimming 220V ballast. This power factor corrected, 60W non-dimming ballast operates over a 187 to 253VRMS line, and is designed to power two series connected F32T8 lamps. The design preserves the features of the dimming ballast, which include: * * * * * * 0.99 minimum power factor Less than 10% THD Programmable starting sequence for low glow current and extended lamp life Greater than 92% efficiency All American On-chip thermal and lamp out detection circuitry Capsco Power down threshold for GFI or end of lamp life protection Future Active Inc. Digi-Key Corp. Premier Magnetics (800) 538-8587 (800) 723-5817, (408) 434-9599 (800) 344-4539 (714) 362-4211 (800) 222-6001 Shaded items in Table 1 indicate changes to the original ML4833 Evaluation Board parts list. VENDOR LIST
CONVERSION
To convert the ML4833 Evaluation Board to the nondimming design described: 1. 2. 3. 4. Remove the dimmer control interface subassembly. Remove components R2,R3, R16, C4, C5 and T5 (as shown in Figure 2). Ground LAMP FB. Replace R24 and C22 with jumpers and change the values of R21 and R5 per Table 1. The new components (R26, R27, C27 and D14) can be assembled using available wiring at T5.
The mode of operation used for preheating and striking of the lamps is the widely accepted variable frequency, nonoverlapping inverter topology. Specific details on power factor correction and resonant lamp network design can be obtained from Application Note 63.
R&D Electronic Parts (800) 675-1177 PCB Engineering (408) 946-2075
EMI Filter
Bridge Rectifier
PFC
Inverter
Lamp Network
198 - 242 VAC
ML4833 Interrupt
Figure 1. Functional Block Diagram
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Application Brief 6
HOT F1 L1 R6 C1 220 VAC C3 L2 NEUTRAL C25 D13 C20 C26 D12 R20 D10 8 C9 R14 C7 R10 1 C24 PDWN R4
PEAO
R7 D8
TP4
D3
D1 6
T1
10 Q1
D7 C10
T2 R11 6 3
R17
Q2
D4 C2
D2
9
8
R12
7
2 R18 Q3 6 1 TP1 7
T4
4 3 2 1 9
R C23 R Y
D9
R8 R13 C17
D5 R1 D6
8 R19
Y B
B
C19
C8 TP5 R22 18 C27
PVFB/OVP
2
PIFB
17 U1 ML4833
VREF VCC PFC OUT
3
PDWN
16 15 14
TP2
4
LAMP FB
5
LFB OUT
OUT A
6 7 R25 8 9
RX/CX RSET RT/CT INTERRUPT
13
OUT B
12
P GND
R26
11
GND
10
CRAMP
D11 C15 C16
D14
R5 R15 C11 C6 TP3 R23 R21 C21 R27
C14 C12
C13
Figure 2. Non-Dimming 220V Schematic
2
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Application Brief 6
TABLE 1. PARTS LIST
QUANTITY
RESISTORS 1 R1 R2 R3 R4 R5 R6, R7, R26, R27 R8 R9 R10 R11, R12 R13 R14 R15 R16 R17, R18, R19 R20 R21 R22 R23, R25 R24 J1 - J11 C1, C2 C3 C4, C5 C6 C7 C8 C9 C10 C11 C12 C13 C14, C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25, C26 C27 1.0, 1/2 W, 5%, metal film not used not used 1.1M, 1/4 W, 1%, metal film 24.9k, 1/4 W, 1%, metal film 51k, 1/4 W, 5%,carbon film 22, 1/4 W, 5%, carbon film not used 17.4k, 1/4 W, 1%, metal film 442k, 1/4 W, 1%, metal film 5.76k, 1/4 W, 1%, metal film 470, 1/4 W, 5%, carbon film 820k, 1/4 W, 5%, carbon film not used - insert jumper 51, 1/4 W, 5%, carbon film 820, 1/4 W, 5%, carbon film 300k, 1/4 W, 5%, metal film 5k potentiometer 200k, 1/4 W, 5%, carbon film not used - insert jumper 0.0 Jumper 2.2nF, 250VAC, 10%, `Y' 0.15F, 300VAC, 10%, `X', not used 1.5nF, 50V, 2.5%, NPO ceramic 22nF, 100V, 5%, ceramic 4700pF, 630V, 5%, polypropylene 15nF, 400V, 5%, polypropylene 47F, 450V, 20%, electrolytic 33nF, 63V, 10% ceramic 680pF, 100V, 5%, ceramic 6.8F, 35V, 20%, electrolytic 0.22F, 50V, 20%, ceramic 100pF, 100V, 5%, ceramic 1.0F, 50V, 20%, electrolytic not used - insert jumper 47F, 16V, 20%, electrolytic 100F, 25V, 20%, electrolytic 1.0F, 50V, 20%, electrolytic not used - insert jumper 120pF, 1kV, 10%, ceramic 47nF 63VDC, 10% ceramic 0.1F, 50V, 5%, polyester film 0.22F, 250V, 5%, polyester film NTE HW1D0
DESIGNATOR
DESCRIPTION
MANUFACTURER PART NUMBER
1 1 2 1 1 2 1 1 1 3 1 1 1 2 11 CAPACITORS 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1
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1.1M-Q 24.9K-X 51K-Q 22-Q 17.4K-X 442K-X 5.76K-X 470-Q 820K-Q 51-Q 820K-Q 300K-Q 3386P-502-ND 200K-Q 0.0-Q MP3-Y MP3-X RPE121COG152 ECU-S2A223JCB MKP10 MKP10 ECE-S2WU470J ECU-S1J333KBA ECU-S2A681JCA ECE-A16Z6R8 RPE123Z5U105M050 SR211A101JAA ECE-A1HU010 ECE-A1CU470 ECE-A1EU101 ECE-A1HU010 ECK-D3A121KBM ECU-S1J473KBA ECQ-V1H04JL ECQ-E2224KF 3
Application Brief 6
TABLE 1. PARTS LIST (Continued)
QUANTITY
DIODES 5 2 1 4 1 1 ICs 1 TRANSISTORS 3 HARDWARE 3 FUSES 1 2 MAGNETICS 1 1 1 1 1 INDUCTORS 2 Ref. F1 Ref. F1 T1 T2 T3 T4 T5 L1, L2 D1 - D4, D8 D5, D6 D7 D9, D11 - D13 D10 D14 U1 Q1 - Q3 1 A, 600 V, 1N4007 (or 1N5061) 1N4001, 1 A, 50 V (or more) BYV26C, 1 A, 600 V ultra fast 1N4148, 0.1 A, 75 V, signal 1N5245B, 15 V, .5 W, Zener 1N5818, 1.0 A, 30V Schottky ML4833 Elec. Ballast Controller IRF820, 2.5A, 500V, power MOSFET TO-220 Heatsink 1A fuse, 5x20mm miniature Fuse Clips, 5x20mm, PC Mount Motorola Motorola GI Motorola Motorola Motorola Micro Linear IR Thermalloy Littelfuse 1N4007TR 1N4001TR BYV26C 1N4148TR 1N5245B 1N5818 ML4833CP IRF820 7173D F945-ND F058-ND
DESIGNATOR
DESCRIPTION
MANUFACTURER PART NUMBER
Boost inductor, 8.0mH Premier Magnetics TDS-965 Gate Drive Xfmr, Lpri = 16mH (min) Premier Magnetics PMGD-04 not used - install jumpers from pin 10 to pin 4, and from pin 5 to pin 6 Inductor, LprI = 5.4mH Premier Magnetics TDS-892 not used EMI/RFI, 600mH, DC resistance = 0.45.
Premium Magnetics
SPE116A
DISCLAIMER FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION OR DESIGN. FAIRCHILD DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS. LIFE SUPPORT POLICY FAIRCHILD'S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR CORPORATION. As used herein: 1. Life support devices or systems are devices or systems which, (a) are intended for surgical implant into the body, or (b) support or sustain life, and (c) whose failure to perform when properly used in accordance with instructions for use provided in the labeling, can be reasonably expected to result in a significant injury of the user. www.fairchildsemi.com 2. A critical component in any component of a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system, or to affect its safety or effectiveness.
(c) 2000 Fairchild Semiconductor Corporation
REV. 1.0 10/25/2000
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