UM10486 UBA2015P reference design 120 V (AC) · 2.2 nF 250 V F1 FUSE HOLDER 20 × 5 mm F3 fuse holder cover, 20 × 5 mm F2 T1A V1 710 V C2 220 nF C21 47 nF C15 100 nF C18 220 nF C20

UM10486UBA2015P reference design 120 V (AC)Rev. 1.1 — 8 September 2011 User manual

Document information

Info Content

Keywords UBA2015P, 2x TL5HE35W ballast

Abstract This document describes the UBA2015P reference design for 120 V (AC).

NXP Semiconductors UM10486UBA2015P reference design 120 V (AC)

Revision history

Rev Date Description

v.1.1 20110908 updated issue

v.1 20110624 first issue

Modifications: • Figure 11 “Schematic diagram” has been updated.

• Bill of Materials (Table 4) has been updated.

UM10486 All information provided in this document is subject to legal disclaimers. © NXP B.V. 2011. All rights reserved.

User manual Rev. 1.1 — 8 September 2011 2 of 18

Contact informationFor more information, please visit: http://www.nxp.com

For sales office addresses, please send an email to: [email protected]


1. Introduction

This document describes the specification and use of the UBA2015P board. This reference ballast design is intended to drive two TL5HE35W lamps.

The Printed-Circuit Board Assembly (PCBA) has the 12NC 7022 001 15932.

Do not power the board without IC. The VDD decoupling capacitor voltage exceeds the rated value when the IC does not limit the voltage to 13 V.

2. Safety warning

Connect the board to the mains voltage. Avoid touching the board at all times when it is connected to the mains voltage. An isolated housing is obligatory when used in uncontrolled, non-laboratory environments. Galvanic isolation of the mains phase using a variable transformer is always recommended.

WARNING

Lethal voltage and fire ignition hazard

The non-insulated high voltages that are present when operating this product, constitute a risk of electric shock, personal injury, death and/or ignition of fire.

This product is intended for evaluation purposes only. It shall be operated in a designated test area by personnel qualified according to local requirements and labor laws to work with non-insulated mains voltages and high-voltage circuits. This product shall never be operated unattended.

Fig 1. UBA2015P reference board

019aac653

a. Isolated b. Non-isolated

Fig 2. Variac isolation symbols

019aab173 019aab174




3. Specifications

4. Board information

4.1 Block diagram

The input section includes:

• The fuse

• Surge protection against fast AC transients

• ElectroMagnetic Interference (EMI) filter

• Full-wave rectifier

• Pre-conditioner or Power Factor Correction (PFC)

The output of the PFC connects to an electrolytic buffer capacitor to supply the half-bridge circuit. The lamp connects to the half-bridge circuit. The UBA2015P controller IC controls the PFC and the half-bridge circuit.

The PFC is implemented as an up converter in boundary conduction mode. The resonant circuit is voltage fed by the half-bridge which consists of two N-channel MOSFETs. The resonant circuit includes a transformer for electrode preheating and heating.

Table 1. Electrical board specification

Description Product(s)

Ballast type electronic

Starting method programmed start with preheat

Starting time < 1 s

Lamp terminals 7

Lamp connection parallel

Line voltage 108 V (AC) to 132 V (AC)

Line frequency 50 Hz/60 Hz

Number of lamps 2

Dimming interface none

Transient protection compatibility IEC61547

Table 2. Supported lamps

Lamp type Description

TL5HE35W 35 W TL5 high-efficiency fluorescent lamp

TL5HE28W 28 W TL5 high-efficiency fluorescent lamp

Table 3. Ballast performance

Lamp type Number of lamps

Rated lamp power (W)

Maximum THD (%)

Maximum lamp current crest factor

Power factor Nominal lamp current (A)

TL5HE35W 2 35 10 1.7 0.98 0.170

TL5HE28W 2 28 10 1.7 0.97 0.170




This type of topology with inductive heating is used in many commercial ballasts whose power exceeds 25 W, making it a cost-effective application.

The lamps are connected in parallel.

4.2 Performance indicators

4.2.1 Input power, power factor and Total Harmonic Distortion (THD)

4.2.2 Lamp end of life detection

IEC asymmetrical power test: The End-Of-Life (EOL) resistor REOL is increased (manually controlled rheostat of 1 k) until the ballast shuts down. A rheostat is a two-terminal variable resistor. See IEC-61347-2-3 Section 17.3 where this test is described. When the EOL voltage exceeds the thresholds of the internal window comparator, the slow fault timer (CPT pin) starts.

Fig 3. Block diagram

019aac299

mainsvoltageinput

FUSE SURGEPROT

EMIFILTER

ACRECTIFIER PFC BUFFER

CAPHALF

BRIDGERESONANT

CIRCUIT

UBA2015CONTROLLER

lamps

(1) Power factor

(2) Current THD

(3) Input power (W)

Fig 4. THD, power factor and input power as a function of AC mains input voltage

Mains voltage (V)90 150130110100 140120

019aac485

77

78

76

79

80

Power(W)

75

0.4

0.6

0.2

0.8

1.0Power factor

THD

0.0

(1)

(3)

(2)




Measurements: P2 = Mean(PEOL) between divisions 4 and 5 on the plot

Traces:

(1) C1 = Z1 = EOL

(2) C2 = Z2 = CPT

(3) F1 = F2 P(REOL)

Fig 5. EOL shutdown triggered by Vth(low)EOL

019aac291




4.2.3 Lamp removal detection

The UBA2015/UBA2016 family has several fast protection features for lamp removal detection:

• Capacitive Mode Protection (CMP)

• Saturation protection

• OverVoltage Protection (OVP)

In this application, overvoltage protection is triggered during lamp removal. Other applications with a different operating frequency with respect to the resonance frequency can be triggered differently. The main function of the IC is to shut down as fast as possible when a lamp is removed.

The fast protection on the VFB pin is repeatedly triggered (VVFB > 3.35 V (typical)) during the lamp removal process. As a result the fast fault detection timer tdet(fault) ends.

In this application, the shutdown is not triggered by pin SLHB because of the 340 ns leading edge blanking time on this pin.

Measurements: P2 = Mean(PEOL) between divisions 4 and 5 on the plot

Traces:

(1) C1 = Z1 = EOL

(2) C2 = Z2 = CPT

(3) F1 = F2 P(REOL)

Fig 6. EOL shutdown triggered by Vth(high)EOL

019aac292




(1) C1 = Z1 = GLHB

(2) C2 = Z2 = SLHB

(3) C3 = Z3 = VFB

(4) C4 = Z4 = SHHB

Fig 7. Shutdown after lamp removal triggered by Vth(ov)(VFB)

019aac293




4.2.4 ElectroMagnetic Interference (EMI) - conducted emission tests

The board with lamp complies with FCC-15 quasi-peak and average measurements, no metal shielding required for acceptable EMI performance. The ballast was tested on a reference luminaire with two TL5HE35W lamps.

Fig 8. Photograph of the EMI conducted emission measurement setup

019aac300




a. Line L

b. Line N

Fig 9. EMI: conducted emission test results

1 PKMAXH

2 AVCLRWR

SGL

6DB

NXP Semiconductors

TDF

dBµVdBµV

9 kHz 30 MHz

OVLD

MT 15 ms

RBW 9 kHz

PREAMP OFFAtt 20 dB

04.May 11 15:16

100 kHz 1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

1

Marker 1 [T2 ]

61.79 dBµV

9.000000000 kHz

FCC15AVQ

FCC15BVQ

019aac486

(1)

(2)

NXP Semiconductors

1 PKMAXH

2 AVCLRWR

SGL

6DB

TDF

dBµVdBµV

9 kHz 30 MHz

OVLD

MT 15 ms04.May 11 15:36

RBW 9 kHz

PREAMP OFFAtt 20 dB

100 kHz 1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

1

Marker 1 [T2 ]

60.66 dBµV

9.000000000 kHz

FCC15AVQ

FCC15BVQ

019aac487

(1)

(2)




5. Wiring diagram

Connect the ballast as shown in Figure 10.

Connect the chassis to ground using mounting hole E1.

Keep the hot wires to the lamps as short as possible (red and blue wires), so parasitic capacitance remains as low as possible.

Fig 10. Wiring diagram

019aac296

BALLAST

J2-7RED

J2-6RED

GREEN/YELLOWJ1-1

BLACKJ1-2

WHITEJ1-3

protective ground

hot

neutral

J2-5BLUE

J2-4BLUE

J2-3BLACK

J2-2GREEN

J2-1GREEN

LAMP

LAMP



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kΩ

MΩ

15

C18 nF

J2

X2

T5H

E35W

180 kΩ

R14

X4

10

4

7X56X65X74X83X92X101

1 2

3 4

7

6

5

4

3

2

1

VDD

X1

T5H

E35W

1 2

3 4

All inform

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Rev. 1.1 —

8 Sep

temb

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f 18

Fig 11. Schematic diagram

180 kΩ

R20.62 Ω

R33.48 kΩ

R18180 kΩ

R201 kΩ

R12464

R191 kΩ

D131N4937

D121N4937

41.2 kΩ

41.2 kΩ

R221 MΩ

R131 Ω

R4562 kΩ

R5562 kΩ

R21

C1

nm

D6

1N4118

R16

10

R

L3A7608000901

3.9 mH

R17

D11

1N4148 D10

1N4148

D5

UF4006

X3

2.2 nF250 V

F1

FUSE HOLDER20 × 5 mm

F3 fuse holder cover,20 × 5 mm

V1710 V

C2220 nF

C2147 nF

C15100 nF 220

C2047 nF

C192.7 nF

C222.7 nF

C410 nF

D31N4007

D11N4007

C3470 nF

C141 nF

D41N4007

D21N4007

C522 μF

Q22SK3567

WB1

1

3

6mains N

4

L1

2 × 3.3 mH

1

10

481 109

AUXPFCGND

GND

GND

8

T2A

T2B1.1 mH

C27220 nF

4.7 Ω

J1

GPFC

GHHB

SHHB

VFB

FBPFC

1

2

3

82 kΩ

R11

33 kΩ

R10

X11GND

jumperlink

1 kΩ

R8

10 kΩ

R6

nm

R7

D71N5244B

C7470 nF

C61 nF

390 kΩ

R9

C16

82 nF C13

200 pFC17

100 nF

C11

100 nF

E13.5 mm

E2 E3 E4

mounting hole3.5 mm non plated

E5 E6

C9

D9

1N4148

D8

1N4148

100 nF

C8

4.7 nFC12

68 nF C10

22 nF

UBA2015Pin socket

GND

GNDGND

GND

GND

U1

11PH/ENFBPFC

FBPFCAUXPFC

AUXPFC

10

12n.c.COMPPFC

9

13CPTAUXPFC

8

14CFGPFC

GPFC 7

15CIFBGND

6

16IREFVDD

VDD 5

17VFBGLHB

GLHB 4

18EOLSHHB

SHHB 3

19IFBFSHB

2

20SLHB

VFB

EOL

SLHBGHHB

GHHB 1

X1

X2 mains L

TMP-3093

chassis

L4C

9 μH

C2368 nF

9

L3C

9 μH

45 L4B

9 μH

5 L3B

9 μH

C2568 nF

C2668 nF

C2468 nF

L4A7608000901

3.9 mH 81Q3

2SK3567GLHB

SLHB

STARTUP

EOL

U

Q1TK12A50D

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)

019aac297

All inform

ation provided

in this docum

ent is subject to leg

al disclaim

ers.©

NX

P B

.V. 2011. A

ll rights reserved.

Rev. 1.1 —

8 Sep

temb

er 2011 13 o

f 18

Fig 12. PCB layout


8. Bill of materials

Table 4. Bill of materials

Item number

Part reference

Description/value Manufacturer Part number

1 C1 2.2 nF; 20 %; 250 V Murata DE1E3KX222MA5B

2 C2 220 nF; 20 %; 310 V Vishay BFC233922224

3 C3 470 nF; 20 %; 400 V Vishay MKP1840447404M

4 C4 10 nF; 20 %, +80 %; 50 V Vishay K103Z15Y5VF5TH5

5 C5 22 F; 20 %; 450 V Panasonic EEU-EB2W220S

6 C6 1 nF; 10 %; 500 V Vishay H102K25X7RL63J5R

7 C7 470 nF; 5 %; 63 V Kemet R82DC3470DQ60J

8 C8 4.7 nF; 10 %; 100 V Kemet SR211C472KAR

9 C9 100 nF; 10 %; 100 V Vishay BFC236525104

10 C10 22 nF; 10 %; 100 V BC components 2222 370 21223

11 C11 100 nF; 10 %; 100 V Vishay BFC236525104

12 C12 68 nF; 5 %; 63 V Kemet MMK5683K63J01L16.5TA182

13 C13 200 pF; 5 %; 100 V Multicomp MC0805N201J101A2.54MM

14 C14 1 nF; 10 %; 50 V Vishay K102K15X7RF5TH5

15 C15 100 nF; 10 %; 100 V Vishay BFC236525104

16 C16 82 nF; 5 %; 63 V Kemet MMK5823M63J01L4BULK

17 C17 100 nF; 10 %; 100 V Vishay BFC236525104

18 C18 220 nF; 10 %; 400 V Xicon 146-MEF2G224K

19 C19 2.7 nF; 5 %; 2000 V Vishay BFC238361272

20 C20 47 nF; 5 %; 100 V Kemet R82EC2470AA60J

21 C21 47 nF; 5 %; 100 V Kemet R82EC2470AA60J

22 C22 2.7 nF; 5 %; 2000 V Vishay BFC238361272

23 C23 68 nF; 10 %; 400 V Epcos B32521C6683K

24 C24 68 nF; 10 %; 400 V Epcos B32521C6683K

25 C25 68 nF; 10 %; 400 V Epcos B32521C6683K

26 C26 68 nF; 10 %; 400 V Epcos B32521C6683K

27 C27 220 nF; 20 %; 310 V Vishay MKP1840447404M

28 D1 1N4007-E3/51 Vishay 1N4007-E3/51

29 D2 1N4007-E3/51 Vishay 1N4007-E3/51

30 D3 1N4007-E3/51 Vishay 1N4007-E3/51

31 D4 1N4007-E3/51 Vishay 1N4007-E3/51

32 D5 UF4006-E3/73 Vishay UF4006-E3/73

33 D6 1N4148 NXP Semiconductors 1N4148,133

34 D7 1N5244B Fairchild Semiconductor 1N5244B








39 D12 1N4937/54; 600 V; 1 A Vishay 1N4937-E3/54

40 D13 1N4937/54; 600 V; 1 A Vishay 1N4937-E3/54

41 D14 1N4007-E3/51 Vishay 1N4007-E3/51

42 F1 fuse holder; 20 5 mm Multicomp MCHTC-15M

43 F2 fuse T1A Schurter 34.3117

44 F3 fuse holder cover; 20 5 mm Multicomp MCHTC-150M

45 J1 PCB mounted screw terminal MKDSN2,5/3-5.08

Phoenix Contact 1888690

46 J2 PCB mounted screw terminal MKDS 1/7-3,81

Phoenix Contact 1727065

47 L1 B82731T2182A020; 2 3.3 mH Epcos B82731T2182A020

48 L3 Transformer; 3.9 mH; 9 H; 9 H

Würth ElektroniK 7608000901

49 L4 Transformer; 3.9 mH; 9 H; 9 H


50 Q1 TK12A50D Toshiba TK12A50D

51 Q2 2SK3567 Toshiba 2SK3567

52 Q3 2SK3567 Toshiba 2SK3567

53 R1 180 k; 5 %; 2 W Welwyn MFP2-180KJI

54 R2 0.62 ; 5 %; 1 W; 500 V KOA Speer MOSX1CT52RR62J

55 R3 3.48 k; 1 %; 0.6 W Vishay MRS25000C3481FCT00

56 R4 562 k; 1 %; 0.6 W Vishay MRS25000C5623FCT00


58 R6 10 k; 1 %; 0.25 W Xicon 271-10K-RC

59 R7 1 k; 1 %; 0.25 W Xicon 271-1K-RC

60 R8 1 k; 1 %; 0.25 W Xicon 271-1K-RC

61 R9 390 k; 1 %; 0.25 W Xicon 271-390K-RC

62 R10 33 k; 1 %; 0.25 W Xicon 271-33K-RC



65 R13 1 ; 5 %; 1 W; 400 V KOA Speer MOSX1/2CT52R1R0J

66 R14 180 k; 5 %; 2 W Welwyn MFP2-180KJI

67 R15 10 M; 1 %; 0.6 W Vishay MRS25000C1005FRP00

68 R16 41.2 k; 1 %; 0.25 W Xicon 271-41.2K-RC

69 R17 41.2 k; 1 %; 0.25 W Xicon1 271-41.2K-RC

70 R18 180 k; 1 %; 0.25 W Xicon 271-180K-RC

71 R19 1 k; 1 %; 0.25 W Xicon 271-1K-RC

72 R20 1 k; 1 %; 0.25 W Xicon 271-1K-RC

73 R21 4.7 ; 20 %; 1.4 W Epcos B57153S479M

74 R22 1 M; 1 %; 0.6 W Vishay MRS25000C1004FCT00

Table 4. Bill of materials …continued

Item number

Part reference





75 T2 Transformer; Lp = 1.1 mH; 2.7 A; Np/Ns = 57


76 U1 UBA2015P NXP Semiconductors UBA2015P

77 V1 275 V (AC); 85 C; 3.5 kA; 710 Vclamp

Littelfuse V10E275P

78 WB1 wire-bridge-4E 3M 923345-04

79 X11 jumper link Fischer Elektro LB 03 G

Table 4. Bill of materials …continued

Item number

Part reference





9. Legal information

9.1 Definitions

Draft — The document is a draft version only. The content is still under internal review and subject to formal approval, which may result in modifications or additions. NXP Semiconductors does not give any representations or warranties as to the accuracy or completeness of information included herein and shall have no liability for the consequences of use of such information.

9.2 Disclaimers

Limited warranty and liability — Information in this document is believed to be accurate and reliable. However, NXP Semiconductors does not give any representations or warranties, expressed or implied, as to the accuracy or completeness of such information and shall have no liability for the consequences of use of such information.

In no event shall NXP Semiconductors be liable for any indirect, incidental, punitive, special or consequential damages (including - without limitation - lost profits, lost savings, business interruption, costs related to the removal or replacement of any products or rework charges) whether or not such damages are based on tort (including negligence), warranty, breach of contract or any other legal theory.

Notwithstanding any damages that customer might incur for any reason whatsoever, NXP Semiconductors’ aggregate and cumulative liability towards customer for the products described herein shall be limited in accordance with the Terms and conditions of commercial sale of NXP Semiconductors.

Right to make changes — NXP Semiconductors reserves the right to make changes to information published in this document, including without limitation specifications and product descriptions, at any time and without notice. This document supersedes and replaces all information supplied prior to the publication hereof.

Suitability for use — NXP Semiconductors products are not designed, authorized or warranted to be suitable for use in life support, life-critical or safety-critical systems or equipment, nor in applications where failure or malfunction of an NXP Semiconductors product can reasonably be expected to result in personal injury, death or severe property or environmental damage. NXP Semiconductors accepts no liability for inclusion and/or use of NXP Semiconductors products in such equipment or applications and therefore such inclusion and/or use is at the customer’s own risk.

Applications — Applications that are described herein for any of these products are for illustrative purposes only. NXP Semiconductors makes no representation or warranty that such applications will be suitable for the specified use without further testing or modification.

Customers are responsible for the design and operation of their applications and products using NXP Semiconductors products, and NXP Semiconductors accepts no liability for any assistance with applications or customer product

design. It is customer’s sole responsibility to determine whether the NXP Semiconductors product is suitable and fit for the customer’s applications and products planned, as well as for the planned application and use of customer’s third party customer(s). Customers should provide appropriate design and operating safeguards to minimize the risks associated with their applications and products.

NXP Semiconductors does not accept any liability related to any default, damage, costs or problem which is based on any weakness or default in the customer’s applications or products, or the application or use by customer’s third party customer(s). Customer is responsible for doing all necessary testing for the customer’s applications and products using NXP Semiconductors products in order to avoid a default of the applications and the products or of the application or use by customer’s third party customer(s). NXP does not accept any liability in this respect.

Export control — This document as well as the item(s) described herein may be subject to export control regulations. Export might require a prior authorization from national authorities.

Evaluation products — This product is provided on an “as is” and “with all faults” basis for evaluation purposes only. NXP Semiconductors, its affiliates and their suppliers expressly disclaim all warranties, whether express, implied or statutory, including but not limited to the implied warranties of non-infringement, merchantability and fitness for a particular purpose. The entire risk as to the quality, or arising out of the use or performance, of this product remains with customer.

In no event shall NXP Semiconductors, its affiliates or their suppliers be liable to customer for any special, indirect, consequential, punitive or incidental damages (including without limitation damages for loss of business, business interruption, loss of use, loss of data or information, and the like) arising out the use of or inability to use the product, whether or not based on tort (including negligence), strict liability, breach of contract, breach of warranty or any other theory, even if advised of the possibility of such damages.

Notwithstanding any damages that customer might incur for any reason whatsoever (including without limitation, all damages referenced above and all direct or general damages), the entire liability of NXP Semiconductors, its affiliates and their suppliers and customer’s exclusive remedy for all of the foregoing shall be limited to actual damages incurred by customer based on reasonable reliance up to the greater of the amount actually paid by customer for the product or five dollars (US$5.00). The foregoing limitations, exclusions and disclaimers shall apply to the maximum extent permitted by applicable law, even if any remedy fails of its essential purpose.

9.3 TrademarksNotice: All referenced brands, product names, service names and trademarks are the property of their respective owners.




10. Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Safety warning . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Board information . . . . . . . . . . . . . . . . . . . . . . . 44.1 Block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Performance indicators. . . . . . . . . . . . . . . . . . . 54.2.1 Input power, power factor

and Total Harmonic Distortion (THD) . . . . . . . . 54.2.2 Lamp end of life detection . . . . . . . . . . . . . . . . 54.2.3 Lamp removal detection . . . . . . . . . . . . . . . . . . 74.2.4 ElectroMagnetic Interference

(EMI) - conducted emission tests . . . . . . . . . . . 9

5 Wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . 11

6 Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7 PCB layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . 14

9 Legal information. . . . . . . . . . . . . . . . . . . . . . . 179.1 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 179.2 Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . 179.3 Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . 17

10 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

© NXP B.V. 2011. All rights reserved.

For more information, please visit: http://www.nxp.comFor sales office addresses, please send an email to: [email protected]

Date of release: 8 September 2011

Document identifier: UM10486

Please be aware that important notices concerning this document and the product(s)described herein, have been included in section ‘Legal information’.

Documents

UM10486 UBA2015P reference design 120 V (AC) · 2.2 nF 250 V F1 FUSE HOLDER 20 × 5 mm F3 fuse holder cover, 20 × 5 mm F2 T1A V1 710 V C2 220 nF C21 47 nF C15 100 nF C18 220 nF C20