August 1997 Application Brief 42022 ML4833 220V Non-Dimming Ballast Design GENERAL DESCRIPTION CONVERSION 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. To convert the ML4833 Evaluation Board to the nondimming design described: 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 * On-chip thermal and lamp out detection circuitry * Power down threshold for GFI or end of lamp life protection 1. Remove the dimmer control interface subassembly. 2. Remove components R2,R3, R16, C4, C5 and T5 (as shown in Figure 2). Ground LAMP FB. 3. Replace R24 and C22 with jumpers and change the values of R21 and R5 per Table 1. 4. The new components (R26, R27, C27 and D14) can be assembled using available wiring at T5. Shaded items in Table 1 indicate changes to the original ML4833 Evaluation Board parts list. VENDOR LIST All American (800) 222-6001 Capsco (800) 538-8587 Future Active Inc. (800) 723-5817, (408) 434-9599 The mode of operation used for preheating and striking of the lamps is the widely accepted variable frequency, nonoverlapping inverter topology. Digi-Key Corp. (800) 344-4539 Premier Magnetics (714) 362-4211 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 EMI Filter Bridge Rectifier PCB Engineering PFC Inverter (408) 946-2075 Lamp Network 198 - 242 VAC ML4833 Interrupt Figure 1. Functional Block Diagram REV. 1.0 10/25/2000 Application Brief 6 HOT F1 L1 R6 C1 D8 220 VAC D1 D3 T1 6 10 C3 L2 TP4 R7 D4 Q1 D2 9 C2 T2 D7 R11 6 3 R12 7 2 Q2 R17 C10 8 T4 NEUTRAL D5 R1 D9 C25 R13 C17 6 1 C20 C26 8 D12 3 2 D13 D6 TP1 1 7 R19 9 8 C9 C19 Y B B C8 C7 TP5 R10 R22 PVFB/OVP PEAO R4 17 2 PIFB PDWN 3 PDWN 4 U1 ML4833 R25 VCC PFC OUT LFB OUT OUT A RSET OUT B RT/CT P GND TP2 16 15 14 13 6 8 VREF LAMP FB 5 7 C27 18 1 C24 R Y D10 R20 R14 R C23 Q3 R18 R8 4 12 R26 11 GND INTERRUPT 10 9 CRAMP RX/CX D14 D11 C15 C16 R5 R23 R15 C11 C6 TP3 C13 C14 C12 R21 R27 C21 Figure 2. Non-Dimming 220V Schematic 2 REV. 1.0 10/25/2000 Application Brief 6 TABLE 1. PARTS LIST QUANTITY DESIGNATOR DESCRIPTION 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 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 MANUFACTURER PART NUMBER RESISTORS 1 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 REV. 1.0 10/25/2000 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 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 Yageo Yageo Yageo Yageo 1.1M-Q 24.9K-X 51K-Q 22-Q Yageo Yageo Yageo Yageo Yageo 17.4K-X 442K-X 5.76K-X 470-Q 820K-Q Yageo Yageo Yageo Bourns Yageo 51-Q 820K-Q 300K-Q 3386P-502-ND 200K-Q Yageo 0.0-Q Wima Wima MP3-Y MP3-X AVX Panasonic Wima Wima Panasonic Panasonic Panasonic Panasonic Murata AVX Panasonic RPE121COG152 ECU-S2A223JCB MKP10 MKP10 ECE-S2WU470J ECU-S1J333KBA ECU-S2A681JCA ECE-A16Z6R8 RPE123Z5U105M050 SR211A101JAA ECE-A1HU010 Panasonic Panasonic Panasonic ECE-A1CU470 ECE-A1EU101 ECE-A1HU010 Panasonic Panasonic Panasonic Panasonic ECK-D3A121KBM ECU-S1J473KBA ECQ-V1H04JL ECQ-E2224KF 3 Application Brief 6 TABLE 1. PARTS LIST (Continued) QUANTITY DESIGNATOR DESCRIPTION MANUFACTURER PART NUMBER DIODES 5 2 1 4 1 1 ICs D1 - D4, D8 D5, D6 D7 D9, D11 - D13 D10 D14 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 Motorola Motorola GI Motorola Motorola Motorola 1N4007TR 1N4001TR BYV26C 1N4148TR 1N5245B 1N5818 1 TRANSISTORS U1 ML4833 Elec. Ballast Controller Micro Linear ML4833CP 3 HARDWARE Q1 - Q3 3 FUSES 1 2 MAGNETICS IRF820, 2.5A, 500V, power MOSFET TO-220 Heatsink Ref. F1 Ref. F1 1 1 T1 T2 1 1 1 INDUCTORS T3 T4 T5 2 L1, L2 1A fuse, 5x20mm miniature Fuse Clips, 5x20mm, PC Mount IR IRF820 Thermalloy 7173D Littelfuse F945-ND F058-ND 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 4 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