IRPLCFL5U
International Rectifier
•
233 Kansas Street, El Segundo, CA 90245
!
USA
CFL Ballast for 26W/Spiral Lamp, 120VAC Input
By Cecilia Contenti
TOPICS COVERED
Overview
Features
Electrical Characteristics
IR2520D Ballast Control IC
Circuit Description
Functional Description
Fault Conditions
RPLCFL5U Layout
Design Procedure to adapt the
design to different lamp types
1. Overview
The IRPLCFL5U reference design is an electronic ballast for driving 26W compact fluorescent
lamps from 120VAC. The circuit provides all of the necessary functions for preheat, ignition and on-
state operation of the lamp and also includes the EMI filter and the rectification stage. The circuit is
built around the IR2520D Ballast Control IC. The IR2520D provides adjustable preheat time, adjust-
able run frequency to set the lamp power, high starting frequency for soft start and to avoid lamp
flash, fault protection for open filament condition and failure to strike, low AC line protection and
auto-restart after line brownout conditions. The IR2520D is a low-cost solution specific for CFL
applications. The IR2520D has only 8 pins and allows the component count for the complete ballast
to be reduced down to 20 components.
2. Features
Programmable run frequency
Programmable preheat time
Open filaments and no-lamp protection
Failure to Strike and deactivated-lamp protection
Low AC line protection
www.irf.com
1
IRPLCFL5U
3. Electrical Characteristics
Input Power: 26W @ 120VAC
Input Current: 375mArms @ 120VAC
Starting Frequency: 100KHz
Average Run Frequency: 40KHz
Ballast turn-on voltage: 70VAC
Ballast turnoff voltage: 45VAC
Input
(VAC)
90
100
110
120
130
Pin
(W)
19
21.4
24.5
25
26.5
Iinrms
(mA)
360
375
380
375
370
Vbusav
(V)
240
260
280
300
320
Freq.
(KHz)
40.3
40.3
40.3
40.3
40.3
PF
0.56
0.6
0.55
0.55
0.55
THD
(%)
114
116
120
120
127
4. IR2520D Ballast Control IC
The IR2520D is intended for driving CFL and TL lamps in CFL or small size ballasts applications.
The IR2520D integrates all of the necessary functions for preheat, ignition and on-state operation of
the lamp, plus, lamp fault protection and low AC-line protection, together with a complete high- and
low-side 600V half-bridge driver, the IR2520D has only 8 pins and fits into a standard SO8 or DIP8
package. The IR2520D has been designed to overcome the disadvantage of discrete self-oscillat-
ing solutions while maintaining low cost.
In the CFL market, the self-oscillating bipolar transistor solution remains very popular. This ap-
proach is very simple in nature but has many disadvantages including: DIAC or additional circuit
required for starting, additional free-wheeling diodes required, operating frequencies determined
by bipolar transistor storage time and toroid saturation (not easy to design, very dependent on
tolerances in production and difficult to set the frequencies precisely), unreliable “always hot” PTC
thermistor used for preheat that often fails in the field, no protection against lamp non-strike or open
filaments conditions, no smooth frequency ramping during ignition, capacitive mode operations,
high crest factor in the lamp current. These drawbacks can result in high susceptibility to components
and load tolerances, short lamp life and/or catastrophic failure of ballast output stage components.
The heart of the IR2520D is a voltage controlled oscillator (VCO) with externally programmable mini-
mum frequency and 0-5VDC analog voltage input. The IC includes adaptive zero-voltage switching
2
www.irf.com
IRPLCFL5U
(ZVS) and non-ZVS protection, as well as integrated bootstrap diode. The IC protects against non-
ZVS by automatically setting the frequency to ensure ZVS. The IC will eventually shut-down if the
non-ZVS condition cannot be achieved.
One of the biggest advantages of the IR2520D is that it incorporates an internal current crest factor
driven shutdown function and it eliminates the need for a high-precision current sensing resistor
that is typically used to detect over current. The IC uses the VS pin and the RDSon of the low-side
half-bridge MOSFET for over-current protection and to detect non-ZVS conditions. An internal 600V
FET connects the VS pin to the VS sensing circuitry and allows for the VS pin to be accurately
measured during the time when pin LO is high, while withstanding the high DC bus voltage during
the other portion of the switching cycle when the high-side FET is turned on and VS is at the DC bus
potential. Please refer to the IR2520D data sheet for further information on the IR2520D including
electrical parameters, state diagram and complete functional description. As a result of the IR2520D
features, the IRPLCFL5U circuit using the IR2520D is a complete CFL solution that offers better
reliability and longer lamp life than self oscillating solutions while reducing component count and
ballast size.
5. Circuit Description
The schematic for IRPLCFL5U is shown in figure 5.1. The BOM with the components values is
shown in table 5.2.
The ballast incorporates a fuse, EMI filter, input rectifier, bus capacitor, half-bridge, control and
output stage. The output stage is the classical resonant circuit consisting of an inductor, LRES, and
a capacitor, CRES. The circuit is built around the IR2520D Ballast Control IC. The IR2520D pro-
vides adjustable preheat time, adjustable run frequency to set the lamp power, high starting fre-
quency (about 2.5 times fmin) to avoid lamp flash, capacitive mode protection for open filament
condition and current crest factor protection for failure to strike or no lamp conditions.
The AC line input voltage is rectified to provide a bus voltage of approximately 300 volts. The start
up resistors, Rsupply1 and Rsupply2, are sized such that they can supply the micro-power current
during under-voltage lockout (UVLO). When VCC exceeds the UVLO+ threshold, the IR2520D
begins to oscillate and the charge pump circuit (CSNUB, DCP1 and DCP2) supplies the current to
VCC that causes the internal 15.6V zener clamp to regulate.
The IR2520D Ballast Control IC controls the frequency of the half-bridge as well as the ballast
states and protection modes such as lamp preheat, lamp ignition, running mode, low AC line
protection and lamp/ballast fault protection.
www.irf.com
3
IRPLCFL5U
RSUPPLY
DCP2
LAMP
DBR2
F1
LF
CBUS1
CVCC
CF
RFMIN
CVCO
DBR1
VCC
1
VB
8
MHS
LRES
IR2520D
COM
2
FMIN
3
VCO
4
HO
7
VS
6
LO
5
CBS
CSNUB
CRES
MLS
DCP1
CBUS2
Fig. 5.1) IRPLCFL5U Circuit Diagram
Item #
1
2
3
4
5
6
7
8
9
10
11
Qty
2
1
1
1
2
1
1
1
1
1
1
Manufacturer
Diodes Inc
Dale
Panasonic
Digikey
Epcos
Digikey
Panasonic
Panasonic
Panasonic
Panasonic
AVX
Johanson
Wima
International
Rectifier
Part Number
S1MBDITR-ND
CW-1/2
ECQ-U2A104ML
P10730-ND
B82145-A1105-J
M5830-ND
EEU-EB2D220
ECJ-3VB1H104K
ECJ-3VF1E474Z
ECY-3YB1E105K
1812AA681J
102S43W681KV
MKP4 Series
IR2520D
Description
1A 1000V SMB Rectifier
Resistor, 0.5Ohm, 1/2W
Capacitor, 0.1uF 250 VAC
EMI Inductor, 1mH 370mA
RF Chockes 1mH 200mA
Capacitor, 22uF 200V
Capacitor, 0.1uF 50V 1206
Capacitor, 0.47uF 25V 1206
Capacitor, 1uF 25V 1206
Capacitor, 680pF 1KV SMT 1812
Capacitor, 4.7nF 1KV Polypropylene
IC, Ballast Driver
F1
CF
LF
Reference
DBR1, DBR2
CBUS1, CBUS2
CBS
CVCO
CVCC
CSNUB
CRES
IC BALLAST
4
www.irf.com
IRPLCFL5U
Item #
12
13
14
15
16
Total
Qty
1
2
2
1
2
21
Manufacturer
VOGT
International
Rectifier
Panasonic
Panasonic
Diodes
Part Number
5750924800
IRFU320
ERJ-8GEYJ754V
ERJ-8ENF6812V
LL4148DICT-ND
Description
Inductor, 2.25mH, 5%, 1Apk
Transistor, MOSFET
Resistor, 750K, 1206
Resistor, 68.1K, 1%, 1206
Diode, 1N4148 SMT DL35
LRES
Reference
MHS, MLS
RSUPPLY1, RSUPPLY2
RFMIN
DCP1, DCP2
TABLE 5.2) IRPLCFL5U Bill Of Materials. Lamp type: Spiral CFL 26W, Line Input Voltage:90-130 VAC.
Note: Different lamp types may require BOM changes.
6. Functional Description
Figure 6.1 shows the voltage across the lamp and the current in the resonant inductor LRES during
Startup, Preheat, Ignition and Run Mode.
Fig. 6.1: Voltage across the lamp (yellow waveform) and current in the resonant inductor (green
waveform) during Startup, Preheat, Ignition and Run Mode
www.irf.com
5