A 1.

2 kW Electronic Ballast for Multiple Lamps, with Dimming Capability

and High-Power-Factor
Roger Gules and Ivo Barbi
Federal University of Santa Catarina -UFSC
Power Electronic Institute - INEP
P.O. Box 5 1 19 - 880 10-970 - Florian6polis-SC-Brazil
Euripedes Martins Simdes
Lupaquai - Industria e Comercio Ltda.
AV. Eng. AntBnio Francisco de Paula Souza,
1771,13043-540 - Campinas - SP - Brazil
Phone: +55-48-33 1-9204 - Fax: +55-48-234-5422 Phone: 019-230-4655 Fax:019-230-7893
E-mail: roger0,ineu.ufsc.br Internet: httD://www.ineD.ufsc.br E-mail: luDacluai@,correionet.com. - br
Abstract- A high-frequency lighting system for fluorescent
lamp is introduced in this paper. The characteristics of the
proposed lighting system are high performance, high power
factor with low input current harmonic distortion, dimming
capability, low current lamps crest factor, and lower cost when
compared with the traditional system with similar
characteristics. The use of this system in place of the
conventional electromagnetic ballast results in lower power
consumption and reduced maintenance cost, because the
electronic system has higher efficiency and longer lamp lifetime
than the electromagnetic ballast. In comparison with the
conventional electronic ballast, the proposed system presents a
significant reduction of cost. This reduction becomes more
meaningful with the growing of the lamp number.
The description of the lighting system, design procedure and
experimental results taken from a 1.2 kW prototype are included
in the paper.
I. INTRODUCTION
Nowadays, the fluorescent lamp is one of the most
popular lighting systems due to the high luminous efficiency,
energy-saving and long lamp lifetime. However, the
fluorescent lamps present a negative incremental impedance
and must be operated in series with a current limiting device
named ballast. The most traditional is the electromagnetic
ballast, composed by a large inductor that presents great
simplicity and low cost. However it must operate at line
frequency (50/60Hz), resulting in high volume and weight,
audible noise, flicker as well as low eficiency.
The high-frequency electronic ballast has been widely
employed as a solution for these problems. This ballast
commonly uses a rectifier stage and a high-frequency inverter
with a resonant filter that transforms the switching converter
output characteristic from a voltage source into a current
source, thus ensuring stable lamp operation. To satisfy the
regulations for harmonic current emissions from electronic
equipment, and to maintain high power quality, a high-power-
factor AC-DC converter can replace the rectifier stage.
Dimming feature in the fluorescent lamps can also be
implemented with electronic ballast, allowing to control the
lamps luminous flux and to optimize the energy delivered to
the lamp, thus providing an important energy saving.
However, all these advantages reached with the use of
electronic ballast have as a consequence an increase in the
lighting system cost when compared with the traditional
electromagnetic ballast. Though the energy savings
compensate the increase of system cost, the higher initial cost
is a problem for the implementation of high efficiency
lighting system.
In order to make the high performance electronic ballast
more competitive, a high efficiency and low cost high-
frequency lighting system is proposed in this paper.
11. PROPOSED LIGHTING SYSTEM
The proposed lighting system is composed by a high-
power-factor rectifier that supplies a high-frequency zero-
voltage-switching (ZVS) inverter. The output voltage of the
AC-DC converter is regulated, maintaining the power of the
lamps constant, even for large variations in the utility voltage.
The DC voltage has a low ripple, resulting a low current
lamps crest factor. The inverter works with imposed
switching frequency, constant duty-cycle and ZVS
commutation. The lighting control is accomplished changing
the inverter switching frequency. The inverter output voltage
is conducted to the resonant filters that provide the lamp
ignition voltage and stable operation after the ignition.
I ,
I I
I I
I 1
Fig. 1. High-frequency lighting system.
A. High-Power-Factor Rectifier
The topology used in this stage is the SEPIC converter
operating in continuous conduction mode (CCM) and
average-current-control [ 11. With the SEPIC converter high-
power-factor (HPF) and the same DC output voltage that a
conventional diodes bridge with capacitive filter, is obtained.
Thus, it is possible to use a full configuration of the lighting
system with HPF, or a low cost configuration with a diodes
bridge and capacitive filter rectifier, without changes in the
following stages (inverter and resonant filters). The power
circuit and the control block diagram of the SEPIC converter,
used as power factor corrector in CCM, is shown in Fig. 2.
0-7803-5160-6/99/$10.00 0 1999 IEEE. 720
The control of the high-power-factor rectifier is based on
the average-current-mode using the dedicated integrated
circuit UC3854.
I
; UC3854
I
I
VOLTAGE
I
I
I
. .-_
I______-______---________________i
Fig. 2. High-Power-Factor Rectifier.
With this technique it is possible to implement a very
simple control circuit for unitary power-factor in CCM
operation and also to provide over-current protection.
The SEPIC converter does not need limitation of inrush
current, because the low value of capacitor C1 between the
source and the capacitive filter CO, limits this current.
The main current and voltage waveforms of the SEPIC
converter in CCM are presented in Fig. 3 and Fig. 4
respectively.
4
1 I
I t
D.T
I
T
Fig.3. Main current waveforms.
t
-vo
- - - - -
-Vin+Vo
Fig.4. Main voltage waveforms.
B. High-Frequency Inverter
A half-bridge high-frequency inverter with zero-voltage-
switching and constant duty-ratio forms the second stage as
shown in Fig. 5. Each fluorescent lamp is connected to a
small high-frequency resonant filter, shown in Fig. 7. The
series capacitor (Cs) of the resonant filter blocks the DC
component of the output voltage.
VDC
FigS. High-frequency inverter.
The main inverter waveforms are presented in Fig. 6.
I
I I
\ / -
is1
vs 1
, i D 1 , v ,
I I
I , J
is2
vs2
iD2 v
Fig.6. Main inverter waveforms.
The half-bridge inverter operates with a switching
frequency above of the resonant filter frequency; thus the
output current is lagged in relation to the output voltage,
allowing zero-voltage-switching.
C. High-Frequency Resonant Filters
The fluorescent lamp can be considered as an open circuit
before its ignition. After reaching the ignition voltage and the
lamp ignition, the lamp behaves as a negative resistance.
The high-frequency LCC resonant filter shown in Fig. 7
has the function of to reach the ignition voltage and to allow a
stable lamp operation at steady state.
cs Lr
Fig.7. High-frequency resonant filter.
The resonant frequency before the lamp ignition is:
721
1
FO =
cs +c p
With the inverter switching frequency equal to the resonant
frequency, the voltage across the lamp increases until the
ignition voltage to be reached. However, if a problem occurs
in the lamp ignition, the voltage and current in the resonant
circuit can reach dangerous values. With an imposed
switching frequency lightly different of resonant frequency, it
is possible to control the maximum values of voltage and
current in the resonant circuit, allowing a safe operation as
shown in (2) and (3) [2].
iLr(t) = 2 .(cos(or - t ) - cos ( os . t ) )
(2)
-.
vDc os
Lr . ( os 2 - o r 2 )
I
.-
OS * VDC
VCp(t) =
Lr. (wr2 - o s 2) ~ s . c e q
(3)
cs . cp
c s - c p
Where: wr =2.z.Fo os =2.n. f Ceq =-
Fig. 8 shows the lamp voltage and resonant inductor
current during the starting process, considering a switching
frequency (f ) different of the resonant frequency (Fo).
Fig.8. Lamp voltage and resonant current in the lamp ignition.
After the ignition, the resonant circuit limits the current at
nominal lamp value. At steady state, the resonant frequency is
lower than the switching frequency, and the resonant filter
becomes a current source, providing soft commutation in the
inverter.
If the lamp presents the rectification effect, where only one
filament can emit thermal electrons, the block capacitor
voltage (VCS) reaches the inverters DC input voltage (VDC)
and the resonance ceases. Using a resonant filter for each
lamp, a failure in a single lamp would not affect the normal
operation of the others lamps. Therefore, in case of failure in
a lamp, the resonant filter provides safe operation of the
system.
The filament preheating can be obtained using a PTC
(Positive Temperature Coefficient) thermistor in parallel with
the capacitor Cp. The PTC resistance and the lamp voltage
are low until the PTC to reach its reference temperature.
When this temperature is reached, the PTC resistance is high
and its influence in the resonant circuit becomes null, then
the lamp ignition voltage is reached.
The resonant filter can be considered as a high-frequency
ballast, and different lamp power and different resonant filter
connected with the inverter may be used.
D. Lighting Control
The lighting control is accomplished by the variation of
the inverter switching frequency. With the increase of the
switching frequency, the resonant filter gain changes,
dimming all the lamps at the same time. Another effect of the
higher switching frequency is that the resonant filter became
more inductive, so ZVS commutation is obtained even with
low power in the lamps.
111. SIMPLIFIED DESIGN EXAMPLE
The input data for a design example of lighting
Input AC voltage:
DC Bus voltage:
Inverter output power:
Lamp Power: PL =60 W
Ignition voltage:
Switching frequency:
A. High-Power-Factor RectiJier
1) Lin and Lm inductors: The inductor Lin is calculated
by the maximum input current ripple. Limiting the current
ripple to 17% of input peak current, the inductance is equal
to:
system are:
VAC =220 V
VDC =300 V
Po =1200 W
Rh4S lamp voltage: VL= l l 0V
Vig =1100 V
f =30 kHz
Lin =0.4.- vAcpk =0. 4. 220*J1 =2.85mH ( 5)
U * f 1. 457. 30-103
The same value is adopted for Lm.
2) Output capacitor CO: The output capacitor is
calculated by the maximum output voltage ripple. Limiting
the voltage ripple to 3% of the nominal value, the output
capacitance is equal to:
(6)
=590pF
1200
-
Po
C O =
2 ne 120 VDC AVO - 2 . n. 120.300 - 9
CO =680pF
3) Capacitor CI: The capacitor C1 is calculated by:
=2.2p
(7)
1
(2. n . 2 - 103y .2.85mH
- -
1
(2. II. 2 . 103y . Lm
Cl =
B. Resonant Filter
I ) Series Capacitor Cs: The series capacitor is defined by:
PL 60
VL I10
IL =- =- =0.5454A
722
15.0.5454 =290nF
- -
(9)
15. IL
c s =
(F) . 2 . R . f 150- 2 X . 30. IO3
Cs =330 nF/4OOV
2) Parallel Capacitor Cp: Considering a resonant current
in the start five times the lamp current and an ignition voltage
of 1100 V, the equivalent resonant filter capacitance will be:
(10)
=13.15nF
5 . I L 5 0.5454
w = . r = 2 x f) Vzg ~ 2 ~ ~ ~ 3 0 ~ 1 0 ~ ) ~ 1 1 0 0 0 '
The capacitor Cp is calculated by:
CeqaCs 14.47.10-9.330.10-9 =13.7nF
Cs - Ceq 330. I 0-9 - 14.47. I 0-9
Cp=13 nF/1.6 kV
(1 1)
c p = - - -
3) Resonant inductor Lr: The resonant inductor is
calculated by:
5.0.5454 - (2. R . 30- IO3). 13.5.10-9. 300 ~
(13)
Lr =
5.0.5454.(2. n.30 10' )2.13.5.
IV. EXPERIMENTAL RESULTS
To verify the practical aspects of the proposed lighting
system, a laboratory prototype was built and tested, following
the simplified design example.
Fig. 9 shows the complete circuit of the high-power-factor
rectifier. The power switch is a high-speed IGBT. The control
and command is implemented with the UC3854, and an
auxiliary source supplies this circuit.
A non-dissipative snubber is used between the output
diode and the switch S1, minimizing the turn-on losses, and
improving the efficiency in 2%.
Fig. 10 shows the complete circuit of the high-frequency
inverter. In this stage two half-bridge inverters connected in
parallel with the DC Bus voltage are used. The two half-
bridge inverters have the same command circuit. Half of the
lamps are connected in each half-bridge.
An over current circuit is used to protection of the
inverters. If a short-circuit in the inverter output to occur, the
current protection will be operate and all the lamps will be
turned off.
The lighting control is accomplished changing manually
the resistance of SG3525 oscillator.
The MOSFET body diodes were used for anti-parallel
diodes.
NdI "p. I bc Snubbcr
_ - - - -
,a IJOaolW
sI-IRPc4HPsow
,
_ ~ _ _ _ - _ _ - - - _ _ - -
Fig.9.High-power-factor rectifier.
6%
LP uc3s25 33
"' 4.11; 6 II
I
Fig. 10. High-frequency inverter.
723
Fig.] 1. Input voltage and current at full load.
(lOOV/div - 5Ndiv - 2ms/div)
Fig 12 presents the same waveforms at minimal load
(30%).
Fig. 12. Input voltage and current at minimal load (30%)
The SEPIC turn-on commutation is presented in Fig. 13,
(1 OOV/div - 2Ndiv - 2mddiv).
This figure shows the low turn-on losses.
Tek Stop: 250MS/s 214 AWS
t :.> I
a
Ch4 5. 00ACk
Fig. 13. S 1 Turn-on commutation (1 OOV/div - 5Ndiv - 2OOnddiv).
Fig. 13 shows the SEPIC turn-off commutation. The
efficiency of the high-power-factor rectifier at fill load is
94%.
TBK St oo: 25OMS/s 35 AUYS
Fig.14. SI Turn-off commutation (IOOV/div - SNdiv - 2OOnddiv).
Fig 15 shows the ZVS commutation in the half-bridge
inverter at full load.
Tek Stop: 100MS/s 316 AC9S
1
c2 Freq
32.80S2kHZ
P
Fig.15. Half-bridge commutation (MI ) at full load
(lOOV/div - 2Ndiv - 5 p Idiv).
The ZVS commutation in the half-bridge inverter at
minimal load (30%) is shown in Fig. 16.
c2 Freq
4 2.8984kHZ
Fig. 16. Half-bridge commutation (MI ) at minimal load
(IOOV/div - 2Ndiv - 5 p Idiv).
Fig 17 shows the output voltage and output current in one
half-bridge inverter at full load.
724
Tek Stop: 100MS/5 26 AC45
CZ Freq
32.8QQZkHZ
connected in series, so the lamp power does not change with
the cable length. A 60 meters cable was tested and the lamp
power was the same obtained with the resonant filter close to
the inverter.
Fig 19 presents the lamp startup. The resonant filter
implemented does not use a filament preheating device.
Tek Stop: SOOkS/s S ACQS
I
Fig.16. Output voltage and output current
in the Half-bridge at nominal load
(IOOV/div - SA/div - Sp /div).
The lamp voltage and resonant inductor current at full
load are presented in Fig 17.
Fig.17. Lamp voltage and resonant inductor current at full load
(IOOV/div-O.SA/div - IOp/div).
The lamp voltage and resonant inductor current at
minimal load are presented in Fig 18.
Fig.18. Lamp voltage and resonant inductor current at minimal load
(lOOV/div - O.SA/div - Sp Idiv).
The cable connecting the resonant filter to the inverter has
a small inductance in relation to the resonant inductance (Lr)
Fig. 19. Lamp voltage and lamp filament current in the startup
(lOOV/div - 2Ndiv - 200p /div).
Fig. 20 shows the current in the resonant filter using two
low resistances instead of the lamp filaments, in order to test
a fail in the start of the lamp. In Fig. 20 it can be observed
that the resonant current is limited to a constant value,
protecting the components of the resonant circuit. The
differences between the waveforms presented in Fig. 20 and
the theoretical waveforms presented in Fig. 8 occur due to the
cables and filaments resistance, which result in a resonant
filter with low quality factor.
The lamp power variation as function of the switching
frequency is presented in Fig. 2 1. Fig. 22 shows the variation
of the RMS resonant inductor current and the RMS lamp
filament current as hnction of the switching frequency.
Tek Stop: 25.OMWS 155 ACqS
Fig.20. Cp capacitor voltage and resonant inductor current, using two low
value resistors in place of the lamp filaments
(lOOOV/div-2A/div-lOps /div).
725
100
90
80
70
60
50
40
30
20
10 I I I I I I
30 35 40 45 50 55
F (kHz)
Fig.21. Lamp power variation as function of the switching frequency.
600
550 I
I I
A .
400
500
450
350
300
m
250
200
30 35 40 45 50 55
F ( kJ w
Fig.22. RMS resonant inductor current (iLr) and RMS lamp filament
current (iF) as function of the switching frequency.
The RMS current in the lamp filament increases with the
frequency and a lamp stable operation is obtained until
42kHz, when the currents start to decrease. For a switching
frequency above 42kHz, the lamp becomes unstable and the
luminous flux is very low. Thus, the lighting can be
controlled softly until 30% of nominal power, as shown in
Fig 21.
The efficiency of the high-frequency inverter at full load
is 95%.
V. CONCLUSIONS
A high-frequency lighting system with fluorescent lamps
is proposed in this paper. The main characteristics of the
lighting system are: high power factor with low input current
harmonic distortion, dimming capability, low current lamps
crest factor, and lower cost when compared with the
traditional system with similar characteristics. The reduction
of lighting system cost becomes more meaningful with the
growing of the lamp number.
The lighting control is implemented changing manually
the inverter switching frequency, and the luminous flux can
be reduced softly until 30% of nominal lamp power. The
lighting control can be automatic, using sensors and circuits
to change the inverter switching frequency. The increase of
switching frequency to reduce the lamp power makes the
resonant filter more inductive, obtained ZVS commutation
even with low power in the lamps.
The resonant filter can be considered as the high-frequency
ballast, and different lamp power and resonant filter
connected with the inverter may be used.
The resonant filter is designed to provide a safe operation
of the lighting system in case of fail in the lamp ignition and
rectification effect. A resonant filter for each lamp is used and
a fail in a single lamp would not affect the normal operation
of the others lamps. The damaged lamp can be replaced on-
line and the resonant filter provides the automatic lamp
reignition.
The filament preheating can be obtained using a PTC
thermistor in parallel with the capacitor Cp of the resonant
filter.
The disadvantage of the proposed lighting system is to turn
off all the lamps if a short-circuit in the inverter output to
occur. A possible solution for this problem could be the use
of an emergency lighting system.
REFERENCES
[I ] C. A. Canesin and I. Barbi, A Unity Power Multiple
Isolated Outputs Switching Mode Power Supply Using a
Single Switch, APEC9 1, March 199 1.
[2] D. R. Caballero and I. Barbi. Electronic System for
Fluorescent Lighting: Contribution for Resonant Converter
Parameters Design. Brazilian Power Electronics Conference,
COBEP91, December 1991, pp. 56-59.
[3] T.-F. Wu, T.-H. Yu and Y.-J. Wu, A Microprocessor-
Based Toggle-Control Lighting System, IEEE Trans.
Industrial Electronics, vol. 45, No. 3, pp. 525-528, J une 1998.
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