IRPLDIM5E User Manual
Contents
1. REFERENCE DESIGN current through the lamp for all 4 1 Feb 08 1 Feb 08 16 04 38 16 05 21 LeCroy zb 3 18 ps 1B ps 1808 V 1808 V 18 ps 1B ps 208 mA rms 2 51 3 V 200 mA 3 116 3 crms 4 219 8 m crms 4 133 2 m 18 ps BWL 10 ps BWL 118 V 118 V DCX 18 V OC 500 MS s 18 V OC 500 MS s 2 V DC 3 DC 188 V 2 V DC 3 DC 188 V 28 DC AUTO 28 DC AUTO Maximum Dim Level Intermediate Dim Level 1 1 Feb 88 1 Feb 88 16 05 51 16 06 22 LeCroy T i 3 I I Um 3 3 18 ps 1B ps 128 V 188 V T T 18 10 SM M rms 3 148 3 V 1 rms 3 167 0 V crms 4 A 58 2 mA crms 4 23 7 mA 10 ps BWL 10 ps BWL 118 v 118 V OC 10 V DCL 500 5 2 10 V DC 500 MS s 2 V DC 3 DC 188 V 2 V DC 3 DC 188 V 28 DC AUTO 28 DC AUTO Intermediate Dim Level 2 Minimum Dim Level Figure 4 4 Lamp Voltage and Arc Current 00802 www irf com Internationa T R Rectifier 25 08 12 41 01 as ene 2 8 20880 mA mms 2 151 4 V crms 4 153 7 mA z c8 1 i DP 2 1 V DLC 100 k5 s Nu 4 DC 0 200 A 4 20 my OC STOPPED Figure 4 5 Lamp Voltage and Arc Current durin2. RD0802 16 www irf com International TOR Rectitier 8 Inductor Specifications Vogt IL 070 503 11 02 Technologies 00 07544 INDUCTOR SPECIFICATION LR CORE SIZE E20 10 6 EF20 GAP LENGTH mm CORE MATERIAL Philips3C85 Siemens N27 or equivalent NOMINALINDUCTANCE 23 1 TEST TEMPERATURE C URNS WIRE DIAMETER mm MAN 1 6 20 10 38 Multistranded 26 awg insulated 5 5 26 awg insulated PHYSICAL LAYOUT Vertical6 Pin Bobbin 945 2 TEST TEMPERATURE 100 MAIN WINDING INDUCTANCE MIN 21 mH Adjust turns for specified Inductance www irf com RD0802 217 Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery amp Lifecycle Information International Rectifier IRPLDIM5E
3. CD that comes with the reference design kit There are of course several alternative low cost micro controllers that could be used equally well to realize this kind of ballast and that contain the same functionality REFERENCE DESIGN Figure 4 1 shows the microcontroller PWM outputs for all 4 dimming level 28 Nov 07 28 Nov 07 12 04 16 12 04 39 2 leCroy 2 leCro 5 ms H 5 ms 1 00 V HULL Lil 1 08 V in La L dl 14 Lil i r 1 4 44 HH 2 2 i i Freq 2 mnn 101 98 Hz Freg 2 181 97 Hz duty 2 nn 99 98 duty 2 mnn 39 90 5 ms BWL 5 ms BWL 118 v DC 118 DC x 2l V DC 5 MS s 2 v DC f 5 MS s 1 V 10 71 2 DC 2 56 V 1 V DCS 71 2 DC 2 56 V 4 20 m DC AUTO 4 20 OC AUTO Maximum Dim Level Intermediate Dim Level 1 28 Nov 07 21 Jan 08 12 05 01 15 20 36 2 LeCroy 2 5 ms H 5 ms 1 00 V n 1 00 V T il I ll HiH Hi HHH I H H Inm 2 H Freq 2 nn 181 94 Hz Freg 2 nn 98 77 Hz dutu 2 nn 13 98 X duty 2 mn 1 91 X 5 ms BWL 5 ms BWL 11
4. the resulting filtered DC dimming control voltage Figure 4 1 The GP1 input of the micro controller 1 2 is also connected to the AC line input voltage through a filter circuit with a very short delay This allows IC2 to detect very rapidly when AC power has been removed and restored The 5V VDD supply storage capacitor C1 is sufficiently large to allow IC2 to continue to run for more than one second after AC power has been removed from the ballast When the AC line is switched off IC2 detects this rapidly and starts a timer from this point If power is restored within one second the dimming level is reduced by one level thus reducing the output square wave duty cycle and reducing the dimming level by one step If the dimming level was already at minimum then it will cycle back to maximum In the case of AC power being removed for more than one second the dimming level will not be changed After C1 has discharged below the minimum VDD operating voltage of IC2 the micro controller will shut off The micro controller that has been used here is a PIC12F629 which contains some EEPROM non volatile memory The EEPROM allows the micro to store the last dim level www irf com RD0802 4 International T R Rectifier setting before shutting down when power is switched off therefore allowing the ballast start up at that same setting when power is restored no matter how long the ballast has been off For the micro controller code please refer to the
5. too far and the lamp extinguishes the VCC voltage will go below VCCUV and the ignition preheat ramp will be reset to re ignite the lamp reliably 2 0 7 oen 1 V D la V DD 1 MS s 28 DCR DC 2 96 V 4 2 V OC i STOPPED Figure 5 2 Brown out conditions CH1 is the VCO voltage CH2 is the VS voltage Lamp Removal When the lamp is removed the IRS2530D uses the Crest Factor Over current Protection to enter the Fault mode and shut down During lamp removal the output stage will transition to a series LC configuration and the frequency will move towards resonance until the inductor saturates The IRS2530D uses the VS sensing circuitry and the RDSon of the low side half bridge MOSFET to measure the MOSFET current for detecting an over current fault Should the peak current exceed the average current by a factor of 5 5 CF gt 5 5 during the on time of LO the IRS2530D will enter Fault Mode where the half bridge is off Performing crest factor measurement provides a relative current measurement that cancels temperature and or tolerance variations of the RDSon of the low side half bridge MOSFET Figure 5 3 shows the voltage across the lamp and the VS voltage when the lower filament of the lamp is removed Figure 5 4 shows these voltages when the upper filament of the lamp is removed In both cases the IRS2530D will enter the Fault Mode and shut down after detecting that the crest factor exceeds 5 during the on tim
6. 8 v oC x 118 v DC xX 21 v DC 5 MS s di v DC 5 MS s 1 V C 71 2 DC 2 56 19 m 035 71 2 DC 2 56 V 4 20 m DC AUTO 4 5 V DC AUTO Intermediate Dim Level 2 www irf com Minimum Dim Level Figure 4 1 Microcontroller PWM Outputs RD0802 International Rectitier REFERENCE DESIGN Figure 4 2 shows the voltage at the DIM pin for all 4 dimming level 28 Nov 07 12 08 34 leCroy LE 28 Nov 07 12 09 12 2 10 ps 0 50 v Freq 2 61 2147 kHz Freq 2 125 629 kHz crms 2 968 2my crms 2 385 2mV 18 ps BWL 10 ps BWL 118 v DC 118 v oC 2 58 mV DC 500 MS s 2 58 mv DC 500 MS s Jl VDS 9 n 1 23 9 i 9 Doa 2 DC 8 57 V 420 mv DC RUTO 4 20 mv DC 5 AUTO Maximum Dim Level Intermediate Dim Level 1 28 Nov 07 21 Jan 08 12 09 48 15 35 51 Freq 2 40 4571 MHz Freq 2 11 9358 MHz crms 2 4 145 8mV crms 2 10 ps BWL 10 ps BWL 118 v DO 118 v DCX 3 58 mV DC 500 MS s 2 58 mV DC 500 MS s 1 Dia 71 2 DC 8 25 V 18 mv 010 2 DC 0 08 V 4 20 mv DC 5 AUTO 4 5 V OC RUTO Intermediate Dim Level 2 Minimum Dim Level Figure 4 2 IRS2530D DIM pin voltages 00802 www irf com Inter
7. Bridge Driver Line 5 B gt gt gt Microcontroller i Pulse Detect 17 ii Dimming Feedback Lamp Fault Figure 2 1 JRPLDIMSE Block Diagram www irf com RD0802 Lamp ternational T R Rectifier 3 Circuit Schematic M mO a a o O lt ty 5 E amp je p IRS2530D T LL L O lt m X gt IR gt N Figure 3 1 RPLDIMSE Circuit Schematic RD0802 EN www irf com Internationa GR Rectifier 4 Functional Description The IRPLDIM5E reference design is built on the IRS2530D DIM8 dimming platform The lamp arc current is detected through RCS after ignition and added to a DC control voltage to provide an AC signal with a positive offset at the DIM pin of IC1 During DIM mode the IRS2530D adjusts the oscillator frequency in order to maintain the amplitude of this feedback signal such that the negative going peak is regulated at the OV reference In this way the peak to peak AC feedback signal amplitude is regulated to twice the DC control voltage level The IRS2530D incorporates a voltage controlled oscillator whereby the voltage at the VCO pin determines the frequency This is also used to realize the preheat and ignition ramp required to start the lamp At switch on the voltage at the VCO pin will steadily rise from OV At OV the frequency will b
8. e at its maximum level which is considerably above the open circuit resonant point As the voltage increases the frequency gradually falls and the voltage at the lamp increases as well as the current in the cathodes This configuration utilizes voltage mode heating which is provided by means of two auxiliary windings on the resonant output inductor of the ballast circuit This method is the simplest and cheapest however current mode heating could be used if an additional transformer were to be added to sense the arc current As the frequency continues to fall the voltage at the ballast output to the lamp increases until it reaches a point where it is sufficient to ignite the lamp At this point arc current begins to flow in the lamp and a feedback signal is produced at the current sense resistor RCS If ignition fails then the IRS2530D will shut down going into a low VCC current fault mode The dimming control reference voltage is provided at the DIM pin of IC1 and generated by the micro controller 2 at output GP2 GP pins refer to general purpose pins of the micro controller which can be configured by software as high impedance inputs or CMOS outputs The DC dimming control voltage is produced by means of an RC integrating filter supplied by a square wave signal The square wave signal is generated by the micro controller which generates a fixed frequency signal with four separate duty cycle modes The higher the duty cycle the higher
9. e of LO Figure 5 5 shows the VS pin inductor current and voltage across lamp when the inductor saturates and the ballast shuts down www irf com RD0802 11 Intemational T R Rectifier z2H Mawv E T 1155227 5 ms HB kV d ms 100 5 ms 1 OC 2 lo V DD 5 E MSs 3 20 mv OC 4 DC 40 STOPPED Figure 5 3 Lower filament removed CH2 is the VS voltage CH4 is the voltage across the lamp 21 7 11 39 08 1 00 kv 10 ms 100 1 1 v DC Eig v DC 3 20 mv DC 2 DC 2 5 5 4 DC 1 38 kV 2 gx EM EX STOPPED Figure 5 4 Upper filament removed CH2 is the VS voltage CH4 is the voltage across the lamp www irf com RDO802 Intemational T R Rectifier 18 lec HT Reading Floppy Disk Urive 15 21 33 1 10 ps 2 v OC i 218 OC MS 5 3 2 DL 4 DC 1 25kV 4 5 DD 2 TOPPED Figure 5 5 Inductor saturation CH1 is the LO voltage CH2 is the VS voltage CH3 is the current through the resonant inductor and CH4 is the voltage across the lamp Figure 5 6 shows the VS voltage and the voltage across the lamp when the IC undergoes reset with a lamp exchange When the lamp is removed crest factor protection is triggered and the IC enters the Fault mode and shuts down Since the lamp is removed LO pins is pulled above VLOSD and the IC goes to UVLO mode When the lamp is re inserted the IC goes back to the Preheat Ign
10. g preheat and ignition It should be noted in this example that the VCO voltage and consequently the ballast frequency varies only by quite a small amount between the four different dimming levels although the lamp arc current varies considerably This is because the system is operating above the point in the dimming response curve known as the knee this is illustrated below Ballast Lamp Operating Characteristic Lamp Current Ballast Running Frequency Figure 4 6 Lamp current against ballast frequency R6 is also required in order to ensure that the DIM pin of IC1 will be biased above OV before the voltage at VCC exceeds the UV threshold at startup This prevents the IRS2530D from shutting down during the first few cycles of hard switching that occur when the half bridge starts to oscillate at maximum frequency RDO802 _9 www irf com ternational TER Rectifier 5 Fault Conditions In case of fault conditions such as open filaments failure to strike or lamp removal the IRS2530D will go into Fault Mode In this mode the internal fault latch is set HO is off LO is open circuit and the IRS2530D consumes an ultra low micro power current The IRS2530D can be reset with a lamp exchange as detected by the LO pin or a recycling of VCC below and back above the UVLO thresholds Failure to Strike At initial turn on of the ballast the frequency will ramp down from fmax toward the resonance frequency When the lamp fai
11. ition mode and the half bridge starts to oscillate again zH Dec HT 18 47 48 EWL Hig DE 188 kS s Von p 4 DC 0 26 4 1 OC STOPPED Figure 5 6 Lamp exchange CH1 is the LO voltage CH2 is the VS voltage and CH4 is the voltage across the lamp www irf com RD0802 13 International REFERENCE DESIGN TOR Rectitier 6 Bill of Materials 1 1 1R 7 IRS2530D Dimming Ballast Control IC 8 pin DIP uController PIR IRFU320 Transistor MOSFET 400V MHSMIS Reference 1 Dimming Ballast Control IC1 8 Controller IC2 IC1 LL4148DICT ND Diode 75V 100mA DL35 DCP2 ZMM5231B 7 Diode Zener 5 1V 500mW MiniMelf D1 D2 7 1 IL 070 503 11 02 Inductor 2 3mH EF20 LRES MKS2 Series Capacitor 47nF 400V 2 i 2 1 M8301 ND Inductor 1mH 200mA 1 1 1 1 P10730 ND Capacitor 0 1uF 275VAC 1 1 1 1 1 1 1 1 1 1 1 1 3 ECA 0JHG331 Capacitor 330UF 6 3V 105C Radial ECJ 3YB1E225K Capacitor 2 2uF 25V 1206 EEU EB2V100 Capacitor 10uF 350V 105C Radial CBUS CBS CH1 6 Panasonic ECJ 3VB1H104K Capacitor 0 1 50V 1206 CH2 C2 C7 ECU V1H222KBM Capacitor 2 2nF 50V 1206 CVCO ECJ 3YB1E684K Capacitor 0 68uF 25V 1206 1 Panasonic ECJ 3YB1E105K Capacitor 1uF 25V 1206 CVCC 0 20 1 5 IG 00 O N 2 Panasonic Ca
12. ls to strike the VCO voltage continues to increase and the frequency continues to decrease until the VCO voltage exceeds VVCOFLT 4 0V typical and the IRS2530D enters Fault Mode and shuts down Figure 5 1 It should be noted that in case of failure to strike the system will operate in capacitive side of resonance but only for short period of time 18 36 28 1 LeCroy T 5s 1 88 kV DC 50 kS s DC 4 DC 1 18kV DC STOPPED A C C3 c ox X c Figure 5 1 Lamp non strike CH1 is the VCO voltage CH4 is the voltage across lamp AC Mains Interrupt Brown Out Conditions This protection relies on the non ZVS circuit of IRS2530D enabled in the Dim Mode During an AC mains interrupt or brown out condition the DC bus can decrease and cause the system to operate too close to or on the capacitive side of resonance The result is non ZVS switching that causes high peak currents to flow in the half bridge MOSFETSs that can damage or destroy them To protect against this the IRS2530D will detect non ZVS by measuring the VS voltage at each rising edge of LO If the voltage is greater than VZVSTH 4 5V typical the IC will reduce the voltage at VCO pin and thus increase the frequency until ZVS is reached again Figure 5 2 www irf com RD0802 10 Intemational T R Rectifier In case the DC bus decreases
13. national T R Rectifier REFERENCE DESIGN Figure 4 3 shows the voltage at the VCO pin and the VS half bridge voltage for all 4 dimming level 24 Jan 08 24 Jan 08 16 57 25 16 58 07 2 2 10 ps 10 ps 1 00 V 1 00 V 1 1 10 ps 10 ps 100 V 100 V T rms 2 3 663 V rms 2 2 326 V Freq 40 8486 kHz Freq 59 6374 kHz 18 ps BWL 10 ps BWL il 19 V DC 10 V DC 1 V OC 500 MS s 2 1 DC 500 MS s 2 V DC _ 1 DC 288 V 2 V DC S 1 DC 288 V 4 20 mv DC AUTO 420 mv DC AUTO Maximum Dim Level Intermediate Dim Level 1 24 Jan 88 24 Jan 88 15 58 85 16 59 53 2 leCro 2 leCro 18 ps 10 ps 1 00 V 1 8080 V 1 1 10 ps 10 ps 100 V 1808 V rms 2 1 779 V rms 2 1 797 V Freg 66 5846 kHz Fregi 65 9677 kHz 10 ps BWL 10 ps BWL 18 v 18 v 1 V DC 500 MS s 1 V DC 500 MS s 2 V DC 1 DC 288 V 2 V DC 1 DC 288 V 4 20 mV DC AUTO 420 DC AUTO Intermediate Dim Level 2 Minimum Dim Level Figure 4 3 RS2530D VCO red and VS yellow pin voltages www irf com 00802 International T R Rectifier Figure 4 4 shows the voltage across the lamp and the dimming level
14. pacitor 10nF 50V 1206 C3 CDIM ECK D3A102KBP Capacitor 1nF 1KV Ceramic disk 2 MKP10 Series Capacitor 4 7nF 1600V CRES TAW MKP472K1K6 Polypropylene LO Panasonic ERJ 8GEYJ106V Resistor 10M 0 25W 1206 R6 EE EM EM ES 2 Panasonic ERJ 8GEYJ154V Resistor 150K 0 25W 1206 R1 R2 EE i 2 3 4 26 Panasonic ERJ 8GEYJ124V Resistor 120K 0 25W 1206 R3 PRLMP2 2 2 2 2 2 2 ENE 1 Diodes Inc MURS160 13 Diode 600V 1A SMB 1 Di 2 2 2 7 8 29 0 3 32 ERJ 8GEYJ102V Resistor 1K 0 25W 1206 ERJ 8GEYJ105V Resistor 1M 0 25W 1206 RLMP2 33 3 Panasonic ERJ 8GEYJ104V Resistor 100K 0 25W 1206 R7 R9 R10 ERJ 8GEYJ152V Resistor 1 5K 0 25W 1206 RVCO ERJ 8GEYJ100V Resistor 10 Ohm 0 25W 1206 RHO RLO Vishay BC gt N DIS Resistor 0 47R 1 2W ____ eee 235 202 Connector 2 terminal 235 204 Connector 4 terminal VCC COM LO 42 Digi key 5000K ND Test Point VCO DIM VLAMP VS pM 43 1 IRPLDIMBE Rev2 PCB Single Layer TABLE 6 1 RPLDIMSE Bill of Materials www irf com RD0802 14 Internationa TOR Rectitier 7 IRPLDIM5E PCB Layout Top Assembly Top Copper www irf com RD0802 15 ternational T R Rectifier Bottom Assembly JJ ZDOC b J amp 5HIU Bottom Copper
15. ternational T R Rectifier IRPLDIMSE 4 Level Switch Dim Fluorescent Ballast using the IRS2530D DIM8 Table of Contents Page GS UGS a de 2 ON 2 SCHOOL GSAS MR ETT 3 4 Functional Description 4 5 Fault Conditions 10 SN INSTR RENE UU T T 14 Z IRPEDIMSE PCB kay OUE uuu cessent conan 15 o MUCO DECC ATOMS a a 17 www irf com RD0802 International T R Rectifier 1 Features Drives 25W CFL Lamp Input Voltage 220VAC High Frequency Operation Lamp Filament Preheating vy v Vv V V V Vv WV 2 Overview Lamp Fault Protection with Auto Restart Low AC Line Brownout Protection Microcontroller driven 4 level power pulse dimming IRS2530D DIM8 HVIC Ballast Controller REFERENCE DESIGN The IRPLDIMSE reference design kit consists of a dimming fluorescent ballast with a microcontroller driven dimming control system providing four fixed levels and actuated by power re cycle pulses of less than one second driving a single 25W CFL lamp The design contains an EMI filter and a dimming ballast control circuit using the IRS2530D This demo board is intended to help with the evaluation of the IRS2530D DIM8 dimming ballast control IC demonstrate PCB layout techniques and serve as an aid in the development of production ballasts using the IRS2530D DIM8 Ballast Control Output Stage EMI Filter Rectifier Half
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