May 1999

Application Note 42044 58W Single Lamp Dimming Ballast

INTRODUCTION
This Application Note contains all the information necessary to convert an ML4835EVAL-L Evaluation Board into a low cost, high performance ballast capable of dimming IEC 58W lamps to within 5% of full luminous intensity. The power factor corrected ML4835 controlled ballast IC provides these outstanding performance features while operating over a 187VRMS to 253VRMS line:
s s

On chip thermal protection and lamp-out detection circuitry. Latching shutdown pin for EOL protection or power limit. Light output control from 100% to 5% in response to a dimming control or sensor. Programmable time interval automatic lamp restarting.

Continuous current mode PFC operation at the ballast inverter frequency for low conducted EMI and diode commutation losses. Less than 10% THD Programmable three frequency starting sequence to extend lamp life, simplify lamp network design, and start lamps at any dim level without full power flashing. Capacitive side lamp ignition to minimize lamp network inductor size and cost.

s s

B EVALUATION BOARD

Figure 1. Single Lamp Connection Diagram

185 to 253 VAC

EMI FILTER

BRIDGE RECTIFIER

PFC

INVERTER

LAMP NETWORK

POWER DETECT ML4835

CURRENT SENSE

REMOTE 0 to 10V SIGNAL

DIMMING INTERFACE ASSEMBLY

Figure 2. Block Diagram

REV. 1.0 10/25/2000

Application Note 76
CONVERSION
To convert the ML4835EVAL-L Evaluation Board into a single lamp 58W ballast design, as shown by the schematic diagram (Figure 4), the items on the evaluation board must be changed to the values designated by the shaded areas in the Parts List. HOW TO OPERATE TABLE 1. TEST RESULTS The following steps will ensure a safe demonstration of this electronic ballast. CAUTION This ballast contains voltage potentials capable of causing serious injury and components which, if they fail, may shatter or explode. Please use extreme caution when operating this board from AC line voltages. The use of protective eye wear is strongly recommended. To safely observe in-circuit waveforms an isolation transformer should be inserted between the AC line and the ballast. Do not operate this ballast with AC voltages outside the design limits. When replacing components on this ballast use only parts (or equivalents) shown in the parts list contained in this Application Note. 1. Clear the work area of conductive and obstructive material and use a shield. 2. Connect the lamp to the PC board as shown in Figure 1 using 18 AWG wires of ANSI designated colors. There are two connections associated with each letter. 3. Connect the AC hot (line) to the black wire from the PC board; neutral, to gray; and earth ground, to green. 4. Connect TP3 to TP1. This forces the oscillator to operate at the preheat frequency. Connect an RMS voltmeter from TP5 to Tp1. 5. Apply an input line voltage of 230V. Adjust R26 until the voltmeter reads 200V. 6. Remove the input voltage and disconnect TP3 from TP1 and the voltmeter from TP5. 7. Apply an input line voltage from 187V to 253V. Note that the lamp will light in 1 to 2 seconds.
9 8 LAMP ARC RESISTANCE (k) 7 6 5 4 3 2 1 0 0.0 0.1 0.2 0.3 0.4 RES FREQ 90 80 70 60 50 40 30 20 10 0.5 0 NETWORK RESPONSE FREQUENCY (kHz)

PERFORMANCE DATA
Use a Variac or adjustable AC source to measure ballast performance across the range of permissible input voltages. A typical ballast will display the performance listed in Table 1 when operated under these test conditions.

Lamp Intensity Input Power Lamp Current THD Filament Voltage Crest Factor Power Factor
Load: IEC 58W lamp; Line: 220VAC

5% 11 23 17 3.9 1.4 0.995

100% 56 460 2.5 2.6 1.4 0.997

Units W mArms % V RMS

Equipment used: Tektronix TDS640 Digitizing Scope, Tektronix 6021 Current Probe, Voltech Digital AC Power Analyzer # PM100

The graph displays the relationship between lamp arc resistance and inverter frequency change as the lamps are dimmed from 100% to 5%.

LAMP CURRENT (ARMS)

Figure 3. Resistance and Frequency Curves

REV. 1.0 10/25/2000

Application Note 76
L1 R4 D8 F1 HOT 230VRMS NEUTRAL D9 R8 C9 R12 1 C6 D14 C7 8 R25 R3 D11 D18 R27 R2 R21 R16 R19 1 2 3 4 5 R17 C17 6 7 8 9 R15 C19 R26 10 PVFB/OVP PEAO PIFB PIFBO LAMP FB LEAO RSET RT2 RT/CT INTRPT REF VCC PFC OUT OUT A OUT B PGND AGND CRAMP PWDET RX/CX 20 19 18 17 16 15 14 13 12 11 R13 R22 C21 R14 R18 C16 TP1 C22 C15 C24 TP3 C27 C25 C26 1 TP2 5 6 D13 T5 10 R10 C32 C31 1 6 9 8 B Y B 10 2 L2 C2 C1 C3 D4 D2 D3 D1 6 9 T1 10 8 Q1 D7 C8 R7 7 2 D17 C5 D10 TP5 L3 Q3 4 3 R R5 TP4 R6 T2 6 3 D16 Q2 R11 R28 R29

D5 R1 D6

R Y

C11

D12

ML4835
C4 C18 C20 R23

C29

D1 3 T1 4

R8 R6 D2 C1 C4 R7 D3 C2 R4 5 6 + 4 Q1 R5 R3 3 2 + U2 8 1

R2 1

R1 U1 5

7 C5 Violet Grey REMOTE MANUAL DIMMER 0 to 10 VDC

DIMMING CONTROL INTERFACE CIRCUIT

C3

Figure 4. Circuit Schematic

REV. 1.0 10/25/2000

Application Note 76
PARTS LIST FOR 58W LAMP BALLAST
ITEM Resistors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Capacitors 26 27 28 29 30 31 32 33 34 35 36 37 QTY 1 1 1 2 2 1 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 1 1 1 1 3 1 1 DESCRIPTION 1W, W, 5%, metal film 750, W, 5%, carbon film 820, W, 5%, carbon film 51k, W, 5%,carbon film 432k, W, 1%, metal film 5.76k, W, 1%, metal film 0.0W Jumper 30, W, 5%, carbon film 150, W, 5%, carbon film 1.0k, W, 5%, carbon film 12.4k, W, 1%, metal film 681k, W, 1%, metal film 10.0k, W, 1%, metal film 20k, W, 5%, carbon film 8.06k, W, 1%, metal film 19.1k, W, 1%, metal film Jumper 76.8k, W, 1%, metal film 360k, W, 5%, carbon film 200k, W, 5%, carbon film not used 100, W, 5%, carbon film 5k potentiometer 100k, W, 5%, carbon film 270k, W, 5%, carbon film 3.3nF, 250VAC, 10%, Y 0.15F, 250VAC, 10%, X 33nF, 63V, 10% ceramic 0.1F, 50V, 5%, polyester film capacitor 100F, 35V, 20%, electrolytic 47F, 450V, 20%, electrolytic 1.0F, 50V, 20%, ceramic not used 3900pF, 630V, 5%, polypropylene Jumper 4.7F, 35V, 20%, electrolytic 82nF 50VDC, 10% ceramic Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Bourns / 3323P-502-ND Any Any Panasonic / ECK-DNS332ME Panasonic / ECQ-U2A154MV Panasonic / ECU-S1J333KBA Panasonic / ECQ-V1H104JL Panasonic / ECE-B1VU101 Panasonic / ECE-S2WU470J Murata / RPE123Z5U105M050 Panasonic / ECQ-P6392JU Any Panasonic / ECE-B1VU4R7S Panasonic / ECU-S1J823KBA VENDOR / PARTS DESIGNATION R1 R2 R3 R4, R5 R6, R7 R8 R9, R24, R30, R31 R10 R11, R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28, R29 C1, C2 C3 C4 C5, C6 C7 C8 C9 C10, C28, C30 C11 C12, C13, C14, C23 C15 C16

Note: Shading denotes those items that must be changed on the ML4835EVAL-L board for single 58W Lamp operation

REV. 1.0 10/25/2000

Application Note 76
PARTS LIST FOR 58W LAMP BALLAST
ITEM QTY DESCRIPTION Capacitors (Continued) 38 1 8.2nF, 50V, 10%, ceramic 39 1 1.5nF, 50V, 10%, ceramic 40 1 1.5F, 50V, 20%, electyrolytic 41 1 1.0nF, 50V, 2.5%, NPO ceramic 42 1 10F, 25V, 20%, electrolytic 43 1 0.47F, 50V, 20%, ceramic 44 1 1.0nF, 50V, 5%, ceramic 45 2 0.22F, 50V, 10%, ceramic 46 1 47F, 16V, 20%, electrolytic 47 1 100pF, 100V, 5%, ceramic 48 1 0.01F, 400V, 5%, polypropylene 49 1 0.33F, 250V, 10%, polyester Diodes 50 5 1A, 600V 51 2 1A, 50V (or more) 52 1 1A, 600V ultra fast 53 7 0.1A, 75V, signal (Continued) VENDOR / PARTS Panasonic / ECU-S1J822KBA Panasonic / ECU-S1J152JCA Panasonic / ECE-A1HKG1R5 AVX / RPE121COG102 Panasonic / ECE-A1EU100 Mallory / M30U474M5 Panasonic / ECU-S1H102JCB AVX / SR305C224KAA Panasonic / ECE-A1CU470 AVX / SR211A101JAA WIMA / MKP10 Panasonic / ECQ-E2334KF Any/ 1N4005TR (or 1N5061) Any / 1N4001TR GI / BYV26C Any / 1N4148TR DESIGNATION C17 C18 C19 C20 C21 C22 C24 C25, C27 C26 C29 C31 C32 D1 - D4, D8 D5, D6 D7 D9, D10, D12, D14, D16, D17, D18 D11 D13 D15, D19 U1 Q1 Q2, Q3 Ref. 57, 58 Ref. 56 F1 Ref. F1

54 55 56 ICs 57 Transistors 58 59 Hardware 60 61 62 63 Assemblies 64 65

1 1

15 V, 0.5W, Zener 5.6V, 0.5W, Zener not used Electronic Ballast Controller 2.5A, 500V, power MOSFET 2.5A, 500V, power MOSFET TO-220 Heatsink IC Socket (20 pin DIP) 1A fuse, 5x20 mm miniature Fuse Clips, 5x20 mm, PC Mount Dimmer Interface Assembly Heatsink Assembly

ITT / 1N4744A Any / 1N5232B

1 1 2 3 1 1 2 1 3

Micro Linear / ML4835CP Any / IRF820 Any / IRF820 Thermalloy / 7173D Amp / 2-640464-3 Littelfuse / F945-ND Littlefuse / F063-ND ML / ML / 546-00001

Note: Shading denotes those items that must be changed on the ML4835EVAL-L board for single 58W Lamp operation

REV. 1.0 10/25/2000

Application Note 76
PARTS LIST FOR 58W LAMP BALLAST
ITEM Magnetics 66 QTY 1 DESCRIPTION Boost inductor, Lpri = 8.0 mH 3%, Core: Magnetics P/N P-42520-EC (E2425 dbl. stk.) 10 pin bobbin, Magnetics P/N PCB2520-TA Primary: 210 turns 26 AWG, start pin 6, end pin 10 Sec #1: 15 turns 34 AWG, start pin 8, end pin 9 Sec #2: 15 turns 34 AWG, start pin 4, end pin 3 (HI-POT 500 VDC between all windings) Gate Drive Transformer, Lpri = 16 mH (min), (not used) (not used) Current Sense Transformer EMI/RFI Inductor, 600H, DC resistance = 0.45 Power Inductor, L = 1.95 mH 3% , Magnetics P/N P-2520-EC core set 10 pin bobbin Magnetics P/N PC-B2520-TA Wind as follows: Primary: 179 turns, 15-38 Litz start pin 10, end pin 6 Sec #1: 2 turns 32 AWG, start pin 4, end pin 3 Sec #2: 2 turns 32 AWG, start pin 2, end pin 1 Sec #3: 2 turns 32 AWG, start pin 8, end pin 9 (INSULATION MUST SUPPORT 700VAC ACROSS AND BETWEEN WINDINGS) (Continued) VENDOR / PARTS Premier Magnetics / TSD-1338 DESIGNATION T1

67 68 69 70 71 72

Premier Magnetics / PMGD-04

T2 T3 T4 T5 L1, L2 L3

1 2 1

Premier Magnetics / TSD-749 Prem Magnetics / SPE116A Premier Magnetics / TSD-1384

Note: Shading denotes those items that must be changed on the ML4835EVAL-L board for single 58W Lamp operation

REV. 1.0 10/25/2000

Application Note 76
PARTS LIST FOR DIMMER CONTROL INTERFACE
ITEM Resistors 1 2 3 4 5 6 7 8 Capacitors 9 10 11 12 13 Diodes 14 15 ICs 16 17 Transistors 18 QTY 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 DESCRIPTION 360, W, 5%, carbon film 1.5k, W, 5%, carbon film 16.2k, W, 1%, metal film 220k, W, 5%, carbon film 1M, W, 5%, carbon film 3.32k, W, 1%, metal film 180, W, 5%, carbon film 0, W 100F, 35V, 20%, electrolytic 2.7nF, 63V, 5%, ceramic 1nF, 50V, 5%, ceramic 10F, 25V, 20%, electrolytic 0.01F, 1kV, 10%, electrolytic 0.1A, 75V, Signal 18V, 5%, Zener Dual Comparator Opto-Isolator Programmable Unijunction Any Any Any Any Any Any Any Any Panasonic / EC-A1VU101 Panasonic / ECU-S1J221JCA Panasonic / ECU-S1H102JCB Panasonic / ECE-A1EU10 Panasonic / ECK-D3A103KBN Motorola / 1N4148TR Motorola / 1N5248 TI / TLC393 QTC / 4N32 Motorola / 2N6027 VENDOR / PARTS DESIGNATION R1 R2 R3 R4 R5 R6, R7 R8 J1 C1 C2 C3 C4 C5 D1, D3 D2 U1 U2 Q1

Note: Shading denotes those items that must be changed on the ML4835EVAL-L board for single 58W Lamp operation

List of Vendors: All American 230 Devcon Drive San Jose, CA 95112 (408) 441-1300 Capsco 1031 Kiel Court Sunnyvale, CA 94089 (408) 734-3020 ext. 304 Future Active Incorporated 11 Cummings Park Woburn, MA 01801 (800) 723-5817 (408) 434-0369 Digi-Key 701 Brooks Ave. South Thief River Falls, MN 56701 1-800-344-4539 Premier Magnetics 2711 Aliso Creek Road, Suite 175 Aliso Viejo, CA 92656 (949) 362-4211

REV. 1.0 10/25/2000

Application Note 76

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 FAIRCHILDS 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.

2000 Fairchild Semiconductor Corporation

REV. 1.0 10/25/2000