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JULY 2000
ML4831* Electronic Ballast Controller
GENERAL DESCRIPTION
The ML4831 is a complete solution for a dimmable, high power factor, high efficiency electronic ballast. Contained in the ML4831 are controllers for "boost" type power factor correction as well as for a dimming ballast. The Power factor circuit uses the average current sensing method with a gain modulator and over-voltage protection. This system produces power factors of better than 0.99 with low input current THD at > 95% efficiency. Special care has been taken in the design of the ML4831 to increase system noise immunity by using a high amplitude oscillator, and a current fed multiplier. An over-voltage protection comparator inhibits the PFC section in the event of a lamp out or lamp failure condition. The ballast section provides for programmable starting scenarios with programmable preheat and lamp out-ofsocket interrupt times. The IC controls lamp output through either frequency modulation using lamp current feedback. The ML4831 is designed using Micro Linear`s SemiStandard tile array technology. Customized versions of this IC, optimized to specific ballast architectures can be made available. Contact Micro Linear or an authorized representative for more information.
FEATURES
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Complete Power Factor Correction and Dimming Ballast Control on one IC Low Distortion, High Efficiency Continuous Boost, Average Current sensing PFC section Programmable Start Scenario for Rapid or Instant Start Lamps Lamp Current feedback for Dimming Control Variable Frequency dimming and starting Programmable Restart for lamp out condition to reduce ballast heating Over-Temperature Shutdown replaces external heat sensor for safety PFC Over-Voltage comparator eliminates output "runaway" due to load removal Large oscillator amplitude and gain modulator improves noise immunity
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* This product is End Of Life as of July 1, 2000
BLOCK DIAGRAM
7 8 R(SET) R(T)/C(T) OSCILLATOR
INTERRUPT LAMP F.B. LFB OUT
9 5 6
OUTPUT DRIVERS R(X)/C(X) PRE-HEAT AND INTERRUPT TIMERS OUT A CONTROL & GATING LOGIC OUT B 14
10
13
PFC OUT 2 4 3 1 18 IA OUT IA+ I(SINE) EA OUT EA-/OVP POWER FACTOR CONTROLLER UNDER-VOLTAGE AND THERMAL SHUTDOWN PGND VCC VREF GND
15
12 16 17 11
1
ML4831
PIN CONFIGURATION
ML4831 18-Pin DIP (P18)
EA OUT IA OUT I(SINE) IA+ LAMP F.B. LFB OUT R(SET) R(T)/C(T) INTERRUPT
1 2 3 4 5 6 7 8 9 18 17 16 15 14 13 12 11 10
EA-/OVP VREF VCC PFC OUT OUT A OUT B P GND GND R(X)/C(X)
TOP VIEW
PIN DESCRIPTION
PIN# NAME FUNCTION PIN# NAME FUNCTION
1 2
EA OUT IA OUT
PFC Error Amplifier output and compensation node Output and compensation node of the PFC average current transconductance amplifier. PFC gain modulator input. Non-inverting input of the PFC average current transconductance amplifier and peak current sense point of the PFC cycle by cycle current limit comparator. Inverting input of an Error Amplifier used to sense (and regulate) lamp arc current. Also the input node for dimming control. Output from the Lamp Current Error Transconductance Amplifier used for lamp current loop compensation External resistor which sets oscillator FMAX, and R(X)/C(X) charging current
8 9
R(T)C(T)
Oscillator timing components
INTERRUPT Input used for lamp-out detection and restart. A voltage greater than 7.5 volts resets the chip and causes a restart after a programmable interval. Sets the timing for the preheat, dimming lockout, and interrupt Ground Power ground for the IC Ballast MOSFET drive output Ballast MOSFET drive output Power Factor MOSFET drive output Positive Supply for the IC Buffered output for the 7.5V voltage reference Inverting input to PFC error amplifier and OVP comparator input
3 4
I(SINE) IA+
10 R(X)/C(X) 11 GND 12 P GND 13 OUT B 14 OUT A 15 PFC OUT 16 VCC 17 VREF 18 EA-/OVP
5
LAMP F.B.
6
LFB OUT
7
R(SET)
2
ML4831
ABSOLUTE MAXIMUM RATINGS
Absolute maximum ratings are those values beyond which the device could be permanently damaged. Absolute maximum ratings are stress ratings only and functional device operation is not implied. Supply Current (ICC) ............................................... 75mA Output Current, Source or Sink (Pins 13, 14, 15) DC ................................................................... 250mA Output Energy (capacitive load per cycle) .............. 1.5 mJ Gain Modulator I(SINE) Input (Pin 3) ..................... 10 mA Analog Inputs (Pins 5, 9, 18) ............... -0.3V to VCC -2V Pin 4 input voltage ........................................... -3V to 2V Maximum Forced Voltage (Pins 1, 6) .......... -0.3V to 7.7V Maximum Forced Current (Pins 1, 2, 6) ................ 20mA Maximum Forced Voltage (Pin 2) .................. -0.3V to 6V Junction Temperature ............................................. 150C Storage Temperature Range ..................... -65C to 150C Lead Temperature (Soldering 10 Sec.) ..................... 260C Thermal Resistance (JA) Plastic DIP-P ................................................... 70C/W
OPERATING CONDITIONS
Temperature Range ML4831C .................................................. 0C to 85C
ELECTRICAL CHARACTERISTICS
Unless otherwise specified, R(SET) = 31.6k, R(T) = 16.2k, C(T) = 1.5nF, TJ = Junction Operating Temperature Range, ICC = 25mA
PARAMETER PFC Current Sense Amplifier (Pins 2, 4) Small Signal Transconductance Input Voltage Range Output Low Output High Source Current Sink Current ISINE = 0mA, VPIN1 = 0V, VPIN4 = -0.3V, RL = ISINE = 1.5mA, VPIN18/4 = 0V, RL = ISINE = 1.5mA, VPIN18/4 = 0V, VPIN2 = 5V ISINE = 0mA, VPIN2 = 0.3V, VPIN4 = -0.3V, VPIN1 = 0V 5.2 130 -0.3 0.2 5.6 -0.3 0.3 3.0 -0.3 50 -0.3 VPIN5/18 = 3V, RL = VPIN5/18 = 2V, RL = VPIN5/18 = 0V, VPIN1/6 = 7V VPIN5/18 = 5V, VPIN1/6 = 0.3V ISINE = 100A, VPIN1 = 3V ISINE = 300A, VPIN1 = 3V ISINE =100A, VPIN1 = 6V ISINE = 300A, VPIN1 = 6V Output Voltage Limit Offset Voltage ISINE = 1.5mA, VPIN18 = 0V ISINE = 0, VPIN18 = 0V ISINE = 150A, VPIN18 = 3V I(SINE) Input Voltage ISINE = 200A 0.8 1.4 7.2 0.2 7.5 -0.2 0.2 80 10.0 -1.0 110 3.5 0.4 200 270 3.5 0.4 6 mhos V V V mA mA CONDITIONS MIN TYP MAX UNITS
PFC Voltage Feedback Amplifier (Pins 1, 18)/Lamp Current Amplifier (Pins 5, 6) Input Offset Voltage Input Bias Current Small Signal Transconductance Input Voltage Range Output Low Output High Source Current Sink Current Gain Modulator Output Voltage 40 130 112 350 865 15 15 1.8 mV mV mV mV mV mV mV V mV A mhos V V V mA mA
3
ML4831
ELECTRICAL CHARACTERISTICS (Continued)
PARAMETER Oscillator Initial accuracy Voltage stability Temperature stability Total Variation Ramp Valley to Peak C(T) Charging Current (FM Modes) VPIN5 = 3V, VPIN8 = 2.5V, VPIN10 = 0.9V (Preheat) VPIN5 = 3V, VPIN8 = 2.5V, VPIN10 = Open C(T) Discharge Current Output Drive Deadtime Reference Section Output Voltage Line regulation Load regulation Temperature stability Total Variation Output Noise Voltage Long Term Stability Short Circuit Current Line, load, temp 10Hz to 10KHz TJ = 125C, 1000 hrs VCC < VCCZ - 0.5V, VREF = 0V 7.35 50 5 -40 TA = 25C, IO = 1mA VCCZ - 3V < VCC < VCCZ - 0.5V 1mA < IO < 20mA 7.4 7.5 2 2 0.4 7.65 7.6 10 15 V mV mV % V V mV mA VPIN8 = 2.5V Line, temperature 69 2.5 -78 -156 5 0.75 TA = 25C VCCZ - 3V < VCC Preheat and Interrupt Timer (Pin 10) (R(X) = 590K, C(X) = 5.6F) Initial Preheat Period Subsequent Preheat Period Start Period Interrupt Period Pin 10 Charging Current Pin 10 Open Circuit Voltage Pin 10 Maximum Voltage Input Bias Current Preheat Lower Threshold Preheat Upper Threshold Interrupt Recovery Threshold Start Period End Threshold Interrupt Input (Pin 9) Interrupt Threshold Input Bias Current 7.35 7.5 -0.3 7.65 -1 V A VPIN10 = 1.2V VCC = 12.3V in UVLO 0.4 7.0 0.8 0.7 2.1 6.3 -19 0.9 7.3 -0.2 1.18 3.36 1.18 6.7 1.1 7.7 s s s s A V V A V V V V
4
ML4831
ELECTRICAL CHARACTERISTICS (Continued)
PARAMETER OVP Comparator (Pin 18) OVP Threshold Hysteresis Propagation Delay Outputs Output Voltage Low IOUT = 20mA IOUT = 200mA Output Voltage High IOUT = -20mA IOUT = -200mA Output Voltage Low in UVLO Output Rise/Fall Time Under-Voltage Lockout and Bias Circuits IC Shunt Voltage (VCCZ) VCCZ Load Regulation VCCZ Total Variation Start-up Current Operating Current Start-up Threshold Shutdown Threshold Shutdown Temperature (TJ) Hysteresis (TJ) ICC = 25mA 25mA < ICC < 68mA Load, Temp VCC 12.3V VCC = VCCZ - 0.5V 12.4 1.3 15 VCCZ - 0.5 VCCZ - 3.5 120 30 12.8 13.5 150 14.2 300 14.6 1.7 19 V mV V mA mA V V C C IOUT = 10mA, VCC = 8V CL = 1000pF VCC - 2.5 VCC - 3.0 0.4 2.1 VCC - 1.9 VCC - 2.2 0.8 50 1.5 0.8 3.0 V V V V V ns 2.6 2.7 0.25 500 2.8 V V ns CONDITIONS MIN TYP MAX UNITS
FUNCTIONAL DESCRIPTION
OVERVIEW The ML4831 consists of an Average Current controlled continuous boost Power Factor front end section with a flexible ballast control section. Start-up and lamp-out retry timing are controlled by the selection of external timing components, allowing for control of a wide variety of different lamp types. The ballast section controls the lamp power using frequency modulation (FM) with additional programmability provided to adjust the VCO frequency range. This allows for the IC to be used with a variety of different output networks. POWER FACTOR SECTION The ML4831 Power Factor section is an average current sensing boost mode PFC control circuit which is architecturally similar to that found in the ML4821. For detailed information on this control architecture, please refer to Application Note 16 and the ML4821 data sheet.
GAIN MODULATOR The ML4831 gain modulator provides high immunity to the disturbances caused by high power switching. The rectified line input sine wave is converted to a current via a dropping resistor. In this way, small amounts of ground noise produce an insignificant effect on the reference to the PWM comparator. The output of the gain modulator appears on the positive terminal of the IA amplifier to form the reference for the current error amplifier. Please refer to Figure 1.
VMUL
where:
[I(SINE) x (VEA - 1.1V)]
4.17mA
(1)
I(SINE) is the current in the dropping resistor, V(EA) is the output of the error amplifier (Pin 1).
The output of the gain modulator is limited to 1.0V.
5
ML4831
AVERAGE CURRENT AND OUTPUT VOLTAGE REGULATION The PWM regulator in the PFC Control section will act to offset the positive voltage caused by the multiplier output by producing an offsetting negative voltage on the current sense resistor at Pin 4. A cycle-by-cycle current limit is included to protect the MOSFET from high speed current transients. When the voltage at Pin 4 goes negative by more than 1V, the PWM cycle is terminated. For more information on compensating the average current and boost voltage error amplifier loops, see ML4821 data sheet. OVERVOLTAGE PROTECTION AND INHIBIT The OVP pin serves to protect the power circuit from being subjected to excessive voltages if the load should change suddenly (lamp removal). A divider from the high voltage DC bus sets the OVP trip level. When the voltage on Pin 18 exceeds 2.75V, the PFC transistors are inhibited. The ballast section will continue to operate. The OVP threshold should be set to a level where the power components are safe to operate, but not so low as to interfere with the boost voltage regulation loop.
18 2.5V - + R1 C2 C1
TRANSCONDUCTANCE AMPLIFIERS The PFC voltage feedback, PFC current sense, and the loop current amplifiers are all implemented as operational transconductance amplifiers. They are designed to have low small signal forward transconductance such that a large value of load resistor (R1) and a low value ceramic capacitor (<1F) can be used for AC coupling (C1) in the frequency compensation network. The compensation network shown in Figure 2 will introduce a zero and a pole at:
fZ = 1 2 R1C1 fP = 1 2 R1C2
(2)
Figure 2. Compensation Network
7
R(SET) OSC + - + UNDER-VOLTAGE AND THERMAL SHUTDOWN - VREF 2.5V
LFB OUT
6
10
R(X)/C(X)
PREHEAT TIMER
LAMP F.B. INTERRUPT
5 9
16 17 11
VCC VREF GND
2
IA OUT
R(T)/C(T)
8
7K - 4 IA + -VMUL+ + 7K - -1V I(SINE) EA OUT +
+ - PWM (PFC) S
R PFC OUT Q 15
OUT A Q
14
T 3 1 18 GAIN MODULATORS Q
OUT B
13
- EA -/OVP 2.5V - + 2.75V + OVP
P GND
12
Figure 1. ML4831 Block Diagram
6
ML4831
Figure 3 shows the output configuration for the operational transconductance amplifiers. BALLAST OUTPUT SECTION The IC controls output power to the lamps via frequency modulation with non-overlapping conduction. This means that both ballast output drivers will be low during the discharging time tDIS of the oscillator capacitor CT. OSCILLATOR The VCO frequency ranges are controlled by the output of the LFB amplifier (Pin 6). As lamp current decreases, Pin 6 rises in voltage, causing the C(T) charging current to decrease, thereby causing the oscillator frequency to decrease. Since the ballast output network attenuates high frequencies, the power to the lamp will be increased.
VREF
CURRENT MIRROR IN OUT
IQ + gmVIN 2
gmVIN 2 io = gmVIN
IQ -
17
IN OUT CURRENT MIRROR
VREF
R(T)
ICHG
CONTROL
R(T)/C(T)
Figure 3. Output Configuration A DC path to ground or VCC at the output of the transconductance amplifiers will introduce an offset error. The magnitude of the offset voltage that will appear at the input is given by VOS = io/gm. For a io of 1uA and a gm of 0.08 mhos the input referred offset will be 12.5mV. Capacitor C1 as shown in Figure 2 is used to block the DC current to minimize the adverse effect of offsets. Slew rate enhancement is incorporated into all of the operational transconductance amplifiers in the ML4831. This improves the recovery of the circuit in response to power up and transient conditions. The response to large signals will be somewhat non-linear as the transconductance amplifiers change from their low to high transconductance mode. This is illustrated in Figure 4.
iO
C(T)
8 1.25/3.75
+ -
5 mA
CLOCK
tDIS VTH = 3.75V
tCHG
C(T)
VTL = 1.25V
0 Linear Slope Region
VIN Differential
Figure 5. Oscillator Block Diagram and Timing The oscillator frequency is determined by the following equations:
FOSC =
and Figure 4. Transconductance Amplifier Characteristics
1 t CHG + tDIS
(3)
V + I R - VTL t CHG = R T CT In REF CH T VREF + ICH R T - VTH
(4)
7
ML4831
The oscillator's minimum frequency is set when ICH = 0 where:
FOSC 1 0.51x R T CT
(5)
This assumes that tCHG >> tDIS. When LFB OUT is high, ICH = 0 and the minimum frequency occurs. The charging current varies according to two control inputs to the oscillator: 1. The output of the preheat timer 2. The voltage at Pin 6 (lamp feedback amplifier output) In preheat condition, charging current is fixed at
ICHG (PREHEAT) = 2.5 R(SET)
To help reduce ballast cost, the ML4831 includes a temperature sensor which will inhibit ballast operation if the IC's junction temperature exceeds 120C. In order to use this sensor in lieu of an external sensor, care should be taken when placing the IC to ensure that it is sensing temperature at the physically appropriate point in the ballast. The ML4831's die temperature can be estimated with the following equation:
TJ TA x PD x 65C / W
(9)
VCC VCCZ V(ON) V(OFF)
(6)
ICC 15mA t
In running mode, charging current decreases as the VPIN6 rises from 0V to VOH of the LAMP FB amplifier. The highest frequency will be attained when ICHG is highest, which is attained when VPIN6 is at 0V:
ICHG(0) = 5 R(SET)
1.3mA
(7)
t
Highest lamp power, and lowest output frequency are attained when VPIN6 is at its maximum output voltage (VOH). In this condition, the minimum operating frequency of the ballast is set per (5) above. For the IC to be used effectively in dimming ballasts with higher Q output networks a larger CT value and lower RT value can be used, to yield a smaller frequency excursion over the control range (VPIN6). The discharge current is set to 5mA. Assuming that IDIS >> IRT:
Figure 6. Typical VCC and ICC Waveforms when the ML4831 is Started with a Bleed Resistor from the Rectified AC Line and Bootstrapped from an Auxiliary Winding.
STARTING, RE-START, PREHEAT AND INTERRUPT The lamp starting scenario implemented in the ML4831 is designed to maximize lamp life and minimize ballast heating during lamp out conditions. The circuit in Figure 7 controls the lamp starting scenarios: Filament preheat and Lamp Out interrupt. C(X) is charged with a current of IR(SET)/4 and discharged through R(X). The voltage at C(X) is initialized to 0.7V (VBE) at power up. The time for C(X) to rise to 3.4V is the filament preheat time. During that time, the oscillator charging current (ICHG) is 2.5/R(SET). This will produce a high frequency for filament preheat, but will not produce sufficient voltage to ignite the lamp. After cathode heating, the inverter frequency drops to FMIN causing a high voltage to appear to ignite the lamp. If the voltage does not drop when the lamp is supposed to have ignited, the lamp voltage feedback coming into Pin 9 rises to above VREF, the C(X) charging current is shut off and the inverter is inhibited until C(X) is discharged by R(X) to the 1.2V threshold. Shutting off the inverter in this manner prevents the inverter from generating excessive heat when the lamp fails to strike or is out of socket. Typically this time is set to be fairly long by choosing a large value of R(X).
tDIS(VCO) 490 x CT
(8)
IC BIAS, UNDER-VOLTAGE LOCKOUT AND THERMAL SHUTDOWN The IC includes a shunt regulator which will limit the voltage at VCC to 13.5 (VCCZ). The IC should be fed with a current limited source, typically derived from the ballast transformer auxiliary winding. When VCC is below VCCZ - 0.7V, the IC draws less than 1.7mA of quiescent current and the outputs are off. This allows the IC to start using a "bleed resistor" from the rectified AC line.
8
ML4831
0.625 R(SET) R(X)/C(X) 10 C(X) R(X) 6.8 + 1.2/6.8 - R 9 INT VREF - + Q S DIMMING LOCKOUT 1.2/3.4 + HEAT -
LFB OUT is ignored by the oscillator until C(X) reaches 6.8V threshold. The lamps are therefore driven to full power and then dimmed. The C(X) pin is clamped to about 7.5V. A summary of the operating frequencies in the various operating modes is shown below. Operating Mode
Preheat
INHIBIT
Operating Frequency
[F(MAX) to F(MIN)] 2 F(MIN) F(MIN) to F(MAX)
Dimming Lock-out Dimming Control
Figure 7. Lamp Preheat and Interrupt Timers
6.8 3.4 R(X)/C(X) 1.2 .65 0 HEAT
DIMMING LOCKOUT
7.5 INT
INHIBIT
Figure 8. Lamp Starting and Restart Timing
9
7 12 11 10 8 9 C6 C7
C12
C5
D5
C25
C26 C4
ML4831
10
R7 D3 1 T1 D4 C11 Q1 + R6 C10 Q3 C17 R11 C19 8 4 R13 10 9 1 4 5 1 T4 T2 7 4 8 5 5 D8 3 2 D7 R12 + Q2 6 8 T5 1 8 C23 R 4 D11 D12 T3 4 2 C22 5 1 3 Y Y R B B R21 R22 C20 D13 R17 R10 R9 R8 R23 C21 R16 1 18 17 16 15 14 13 2 3 4 5 6
ML4831
F1
L1
L
120V
C1
D1
G
C3
L2
C2
D2
APPLICATIONS POWER FACTOR CORRECTED FLUORESCENT DIMMING LAMP BALLAST
N
+ C13
+ C14 C24 C15 C16
D6 R2 R3 R5 R24
R14
R1
R4
Figure 9. Typical Application: 2-Lamp Isolated Dimming Ballast with Active Power Factor Correction for 120VAC Input
R15
ML4831
TABLE 1: PARTS LIST FOR THE ML4831EVAL EVALUATION KIT
CAPACITORS QTY.
2 1 4 2 1 2 1 1 1 3 1 1 1 1 1 1 1
REF.
C1, 2 C3 C4, 8, 9, 22 C5, 21 C6 C7, 12 C10 C11 C13 C14, 15, 17 C16 C19 C20 C23 C24 C25 C26
DESCRIPTION
3.3nF, 125VAC, 10%, ceramic, "Y" capacitor 0.33F, 250VAC, "X", capacitor 0.1F, 50V, 10%, ceramic capacitor 0.01F, 50V, 10%, ceramic capacitor 1.5F, 50V, 2.5%, NPO ceramic capacitor 1F, 50V, 20%, ceramic capacitor 100F, 25V, 20%, electrolytic capacitor 100F, 250V, 20%, electrolytic capacitor 4.7F, 50V, 20%, electrolytic capacitor 0.22F, 50V, 10%, ceramic capacitor 1.5F, 50V, 10%, ceramic capacitor 22nF, 630V, 5%, polypropylene capacitor 0.1F, 250V, 5%, polypropylene capacitor 0.068F, 160V, 5%, polypropylene capacitor 220F, 16V, 20%, electrolytic capacitor 47nF, 50V, 10%, ceramic capacitor 330pF, 50V, 10%, ceramic capacitor
MFR.
Panasonic Panasonic AVX AVX AVX AVX Panasonic Panasonic Panasonic AVX AVX WIMA WIMA WIMA Panasonic AVX AVX
PART NUMBER
ECK-DNS332ME ECQ-U2A334MV SR215C104KAA SR211C103KAA RPE121COG152 SR305E105MAA ECE-A1EFS101 ECE-S2EG101E ECE-A50Z4R7 SR305C224KAA SR151V152KAA MKP10, 22nF, 630V, 5% MKP10, 0.1F, 250V, 5% MKP4, 68nF, 160V, 5% ECE-A16Z220 SR211C472KAA SR151A331JAA
RESISTORS: 1 1 1 1 1 1 1 3 1 1 1 1 R1 R2 R3 R4 R5 R6 R7 R8, 22, 11 R9 R10 R12 R13 0.33, 5%, 1/2W, metal film resistor 4.3K, 1/4W, 5%, carbon film resistor 47K, 1/4W, 5%, carbon film resistor 12K, 1/4W, 5%, carbon film resistor 20K, 1/4W, 1%, metal film resistor 360K, 1/4W, 5%, carbon film resistor 36K, 1W, 5%, carbon film resistor 22, 1/4W, 5%, carbon film resistor 402K, 1/4W, 1%, metal film resistor 17.8K, 1/4W, 1%, metal film resistor 475K, 1/4W, 1%, metal film resistor 5.49K, 1/4W, 1%, metal film resistor NTE Yageo Yageo Yageo Dale Yageo Yageo Yageo Dale Dale Dale Dale HWD33 4.3K-Q 47K-Q 12K-Q SMA4-20K-1 360K-Q 36KW-1-ND 22-Q SMA4-402K-1 SMA4-17.8K-1 SMA4-475K-1 SMA4-5.49K-1
11
ML4831
TABLE 1: PARTS LIST FOR ML4831EVAL EVALUATION KIT (Continued)
RESISTORS: (Continued) QTY.
4 1 1 1 1
REF.
DESCRIPTION
MFR.
Yageo Yageo Dale Yageo Bourns
PART NUMBER
100K-Q 681K-Q SMA4-10K-1 33-Q 3386P-253-ND
R14, 17, 24, 25 100K, 1/4W, 5%, carbon film resistor R15 R16 R21 R23 681K, 1/4W, 5%, carbon film resistor 10K, 1/4W, 1%, metal film resistor 33, 1/4W, 5%, carbon film resistor 25K, pot (for dimming adjustment)
DIODES: 4 2 1 5 IC's: 1 IC1 ML4831, Electronic Ballast Controller IC Micro Linear ML4831CP D1, 2, 3, 4 D5, 6 D7 D8, 9, 11, 12, 13 1A, 600V, 1N4007 diode (or 1N5061 as a substitute) 1A, 50V (or more), 1N4001 diodes 3A, 400V, BYV26C or BYT03 400 fast recovery or MUR440 Motorola ultra Fast diode 0.1A, 75V, 1N4148 signal diode Motorola Motorola GI Motorola 1N4007TR 1N4001TR BYV26C 1N4148TR
TRANSISTORS: 3 Q1, 2, 3 3.3A, 400V, IRF720 power MOSFET IR IR720
MAGNETICS: 1 T1 T1 Boost Inductor, E24/25, 1mH, Custom Coils P/N 5039 or Coiltronics P/N CTX05-12538-1 E24/25 core set, TDK PC40 material 8-pin vertical bobbin (Cosmo #4564-3-419), Wind as follows: 195 turns 25AWG magnet wire, start pin #1, end pin #4 1 layer mylar tape 14 turns 26AWG magnet wire, start pin #3, end pin #2 NOTE: Gap for 1mH 5% T2 Gate Drive Xfmr, LPRI = 3mH, Custom Coils P/N 5037 or Coiltronics P/N CTX05-12539-1 Toroid Magnetics YW-41305-TC Wind as follows: Primary = 25 turns 30AWG magnet wire, start pin #1, end pin #4 Secondary = 50 turns 30AWG magnet wire, start pin #5, end pin #8
1
T2
12
ML4831
TABLE 1: PARTS LIST FOR ML4831EVAL EVALUATION KIT (Continued)
MAGNETICS: (Continued) QTY.
1 T3
REF.
DESCRIPTION
MFR.
PART NUMBER
T3 Inductor, LPRI = 1.66mH, Custom Ciols P/N 5041 or Coiltronics P/N CTX05-12547-1 E24/25 core set, TDK PC40 material 10 pin horizontal bobbin (Plastron #0722B-31-80) Wind as follows: 1st: 170T of 25AWG magnet wire; start pin #10, end pin #9. 1 layer of mylar tape 2nd: 5T of #32 magnet wire; start pin #2, end pin #1 1 layer of mylar tape 3rd: 3T of #30 Kynar coated wire; start pin #4, end pin #5 4th: 3T of #30 Kynar coated wire; start pin #3, end pin #6 5th: 3T of #30 Kynar coated wire; start pin #7, end pin #8 NOTE: Gap for 1.66mH 5% (pins 9 to 10) T4 Power Xfmr, LPRI = 3.87mH, Custom Ciols P/N 5038 or Coiltronics P/N CTX05-12545-1 E24/25 core set, TDK PC40 material 8 pin vertical bobbin (Cosmo #4564-3-419) Wind as follows: 1st: 200T of 30AWG magnet wire; start pin #1, end pin #4. 1 layer of mylar tape 2nd: 300T of 32AWG magnet wire; start pin #5, end pin #8 NOTE: Gap for inductance primary: (pins 1 to 4) @ 3.87mH 5% T5 Current Sense Inductor, Custom Coils P/N 5040 or Coiltronics P/N CTX05-12546-1 Toroid Magnetics YW-41305-TC Wind as follows: Primary = 3T 30AWG magnet coated wire, start pin #1, end pin #4 Secondary = 400T 35AWG magnet wire, start pin #5, end pin #8
1
T4
1
T5
INDUCTORS: 2 FUSES: 1 2 HARDWARE: 1 2 3 Single TO-220 Heatsink Double TO-220 Heatsink MICA Insulators Aavid Eng. IERC Keystone PB1ST-69 PSE1-2TC 4673K-ND F1 2A fuse, 5 x 20mm miniature Fuse Clips, 5 x 20mm, PC Mount Littlefuse F948-ND F058-ND L1, 2 EMI/RFI Inductor, 600H, DC resistance = 0.45 Prem. Magnetics SPE116A
13
ML4831
PHYSICAL DIMENSIONS inches (millimeters)
Package: P18 18-Pin PDIP
0.890 - 0.910 (22.60 - 23.12) 18
PIN 1 ID
0.240 - 0.260 0.295 - 0.325 (6.09 - 6.61) (7.49 - 8.26)
0.045 MIN (1.14 MIN) (4 PLACES)
1 0.050 - 0.065 (1.27 - 1.65) 0.100 BSC (2.54 BSC) 0.015 MIN (0.38 MIN)
0.170 MAX (4.32 MAX)
0.125 MIN (3.18 MIN)
0.016 - 0.022 (0.40 - 0.56)
SEATING PLANE
0 - 15
0.008 - 0.012 (0.20 - 0.31)
ORDERING INFORMATION
PART NUMBER ML4831CP TEMPERATURE RANGE 0C to 85C PACKAGE Molded PDIP (P18) (END OF LIFE)
(c) Micro Linear 1997 Micro Linear is a registered trademark of Micro Linear Corporation Products described in this document may be covered by one or more of the following patents, U.S.: 4,897,611; 4,964,026; 5,027,116; 5,281,862; 5,283,483; 5,418,502; 5,508,570; 5,510,727; 5,523,940; 5,546,017; 5,559,470; 5,565,761; 5,592,128; 5,594,376; Japan: 2598946. Other patents are pending.
Micro Linear reserves the right to make changes to any product herein to improve reliability, function or design. Micro Linear does not assume any liability arising out of the application or use of any product described herein, neither does it convey any license under its patent right nor the rights of others. The circuits contained in this data sheet are offered as possible applications only. Micro Linear makes no warranties or representations as to whether the illustrated circuits infringe any intellectual property rights of others, and will accept no responsibility or liability for use of any application herein. The customer is urged to consult with appropriate legal counsel before deciding on a particular application.
2092 Concourse Drive San Jose, CA 95131 Tel: 408/433-5200 Fax: 408/432-0295
DS4831-01
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