This is only a preview of the November 1993 issue of Silicon Chip. You can view 33 of the 96 pages in the full issue, including the advertisments. For full access, purchase the issue for $10.00 or subscribe for access to the latest issues. Articles in this series:
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Items relevant to "High Efficiency Inverter For Fluorescent Tubes":
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A high efficiency
inverter for
f luorescent tubes
This high efficiency inverter will power either
an 18W or 36W slimline fluorescent tube from
a 12V battery. It can be used for camping,
emergency lighting or as part of a solar powered
lighting installation for remote areas.
By JOHN CLARKE
Fluorescent lighting has many
benefits over incandescent lamps.
Fluorescent tubes use far less power
than the equivalent light output incandescent lamps. They also provide
a relatively diffuse light since the light
is emitted from a large surface rather
than from the virtual point source of
a light bulb.
Battery powered fluorescent inverters are very common these days. You
can find them in small portable lamps,
in caravan, bus and boat lighting and
in automotive inspection lamps. In
most of these, a self-oscillating single
transistor inverter steps up the voltage
26 Silicon Chip
from the battery to a high AC voltage
sufficient to start the tube. Once the
tube is lit, the inverter transformer
then provides current limiting for
safe operation. This is a simple system that works but it does have a few
problems.
Firstly, these simple inverters are
not very efficient. This is because the
inverter must provide a very high
voltage (usually in excess of 1000V
AC) in order to start the tube but only
deliver 100V or less once the tube has
fired. This means there are considerable losses in the inverter transformer
and to a lesser extent in the transistor
drive circuitry. Because of this, simple
inverters are rarely practical for tubes
of more than 20 watts output.
Another problem with simple inverters for fluorescent tubes is their
lack of voltage regulation. This makes
no allowance for the fact that the voltage across a battery falls as it becomes
discharged. Consequently, the tube
may be over-bright on a fully charged
battery and become noticeably dimmer
as the battery discharges.
A consequence of brute force starting and overdriving when running
is shortened tube life. For maximum
life, they must be started correctly
and some form of regulation must be
included to avoid overdriving the tube
when the battery voltage is high.
Our new inverter design overcomes
the above shortcomings and has high
efficiency. It can be made to suit 18W
and 20W tubes or 36W and 40W tubes.
The tube filaments are preheated for
correct starting and the circuit incorporates voltage regulation so that the
tubes will have long life. Furthermore,
MOSFET
DRIVERS AND
CONTROLLER
FEEDBACK
START-UP
CIRCUIT
+340V
12V
BATTERY
STEP-UP
TRANSFORMER
AC
RECTIFIER
AND
FILTER
The 340VDC is applied to the fluorescent tube driver circuit. This is
essentially a free-running oscillator
once the tube is running but a start-up
circuit is required to allow the tube
to fire. The start-up circuit applies a
pulse train to the oscillator and if a
tube is connected, the oscillator runs
at a frequency set by the series inductor
(L) and resonant capacitor (C) across
one end of each tube filament. The
resulting current through the resonant
capacitor heats up the tube filaments
and allows the tube to fire.
The circuit then changes to a different operating mode. Inductor L
limits the current to the tube and the
operating frequency becomes lower
as set by a saturable transformer. The
AC capacitor is used to prevent DC
being applied to the tube. DC can cause
mercury migration to one end of the
tube which will ultimately reduce the
operating life.
0V
OSCILLATOR
WITH
SATURABLE
TRANSFORMER
FLUORESCENT TUBE DRIVER
DC-DC CONVERTER
Circuit details
AC
CAPACITOR
INDUCTOR
(L)
FLUORESCENT TUBE
RESONANT
CAPACITOR
(C)
Fig.1: this block diagram shows the main circuit features of the fluorescent
inverter. Note the feedback to maintain a constant DC voltage from the rectifier
output. This ensures constant brightness with varying battery input voltage.
since the tubes are run at a very high
frequency, there is no flicker, either
at start-up or during running. Nor is
there is any hum or audible whistle
and radio interference is low.
The inverter is designed to be
housed in a standard 18W or 36W
batten fitting so that the fluorescent
inverter and lamp are an integral unit.
Block diagram
Fig.1 shows the block diagram of the
fluorescent inverter circuit. It comprises a DC-DC converter (which steps the
12V up to 340V DC) and a fluorescent
tube driver circuit.
The DC-DC converter employs a
step-up transformer which is driven
by two Mosfet transistors at a frequency of around 120kHz, as set by a
switchmode controller IC. The resulting high voltage AC output from the
transformer is rectified and filtered
to provide DC. Feedback is applied
from the output to the switchmode
controller IC to maintain the DC
voltage at 340V.
•
•
•
•
•
•
•
•
•
Main Features
Suitable for 18W and 20W or
36W and 40W tubes
High efficiency
Fast starting without flicker
Filaments preheated
Constant lamp brightness from
11-14.4V supply
Light output equal to conventional
mains-powered lamp
Reverse polarity fuse protection
Fuse protection for faulty tube
Low electromagnetic radiation
The full circuit for the fluorescent
inverter is shown in Fig.2. At the
heart of the DC-DC converter is IC1, a
TL494 pulse width modulation (PWM)
controller. It contains a sawtooth
oscillator, two error amplifiers and a
pulse width modulation comparator.
It also includes a “dead time” control
comparator, a 5V reference and output
control options for push-pull or single
ended operation.
Oscillator components at pins 5 and
6 set the operating frequency of the
pulse width control at about 120kHz.
This frequency was selected to obtain
the maximum power output from the
transformer. The PWM controller
generates variable width output pulses
at pins 9 and 10, to ultimately drive
the gates of Mosfets Q1 and Q2 via
paralleled buffers in IC2.
Mosfets Q1 and Q2 drive the centre
tapped primary winding of transformer T1. The centre-tap of the transformer’s primary winding connects to the
+12V supply while each side of the
prim
ary winding is connected to a
separate Mosfet. Each Mosfet is driven
with a square wave signal so that when
Q1 is on, Q2 is off and when Q2 is on,
Q1 is off.
With Q1 on, 12V is applied to the
top half of the transformer primary
winding. Because of transformer
action, the lower half of the transformer primary winding also has 12V
across it. Similarly, when Q2 turns
November 1993 27
Q4
BUK457-600B
S
G
N3
330
1W
330
ZD3
12V
1W
on, 12V is also impressed across the
top primary winding. The resulting
24V peak-to-peak waveform on the
primary is then stepped up by the
secondary winding.
High speed diodes D1-D4 rectify
the AC output from transformer T1,
while a 0.1µF 250VAC capacitor filters the rectifier output to provide a
stable voltage. We can get away with
such a small value filter capacitor
here because the operating frequency
is so high.
36W AND 18W FLUORESCENT INVERTER
8.2k
3T
6T 0.4mm DIA ENCU
N3
N2
24T
N1
F2
400mA
200mA
F1
5A
2A
FL1
18W
4
E1
9
36W
11
1k
7
9
14
1k
10
E2
16 7
IN(+)
.001
5
15
13
4.7k
2
1M
0.1
47k
14
5V
IN(-)
FB
GDS
4.7k
6
IC1
TL494
1
8
11
12
3
GND
16T
12
8
15
2
3
1
IC2
4050
5
0.1
6T
470
25VW
G
6
S
D
Q2
MTP3055E
10
S
D
G
Q1
MTP3055E
4
0.1
ZD1
16V
1W
470
25VW
82
F1
+12V
28 Silicon Chip
3T 0.25mm DIA ENCU
470
25VW
S2
4T
F2
L1
10uH
S1
4T
F1
T1
0.1
FEEDBACK
D3
270k
270k
0.1
63V
DIAC1
ST2
22
680pF N1
3kV
N2
D4
150k
D5
1N4936
150k
330
1W
330
330
1W
D1
D2
150k
150k
136T
0.1
250VAC
4x1N4936
+340V
T2
330
1W
ZD2
12V
1W
L2
900uH
Q3
BUK457-600B
D
G
S
D
.001
3kV
F2
0.1
250VAC
FL1
Fig.2: the complete circuit of the
fluorescent inverter. The DC-DC
inverter section runs at about 120kHz
while the fluorescent driver section
runs at 65kHz for 36W tubes and
110kHz for 18W tubes.
Feedback
Feedback from the high voltage
DC output is derived from a resistive
divider (two 270kΩ and an 8.2kΩ
resistor) and applied to the internal
error amplifier in IC1 at pin 1. If the
DC voltage becomes greater than 340V,
the pulse width drive to the Mosfets
is reduced until the correct voltage
is obtained. Similarly, if the voltage
drops below 340V, the pulse width is
increased until the correct voltage is
achieved.
The DC gain of the error amplifier
is 213 times, as set by the 1MΩ and
4.7kΩ resistors at pin 2. The 47kΩ
resistor and 0.1µF capacitor across the
1MΩ feedback resistor provide fast AC
response from the circuit.
Power to IC1 and IC2 is supplied
via an 82Ω resistor from the +12V
battery supply and filtered with a
470µF capacitor. A 16V zener diode
protects the circuit from high voltage
transients.
To eliminate RF noise generated by
the switchmode DC-DC converter from
being radiated by the supply leads
we have included a filter comprising
inductor L1 and a 0.1µF capacitor (at
the input).
Fluorescent driver
The fluorescent tube driver comprises Mosfets Q3 and Q4, transformer
T2 and associated components. The
fluorescent tube is driven via inductor
L2 and the N1 winding of transformer
This photo shows the gate drive pulses to Q1 & Q2 in the
DC-DC converter when driving an 18W tube. The gate
pulse width will be greater when the circuit is driving a
36W fluorescent lamp.
T2. The N1 winding drives the gates
of the Q3 and Q4 Mosfets via the N2
and N3 windings which are antiphase
connected.
When power is first applied, there is
340V DC between the drain of Q3 and
the source of Q4. The 0.1µF capacitor
adjacent to Diac1 begins to charge via
the two series 150kΩ resistors. When
the voltage reaches about 30V, the Diac
fires and discharges into the gate of
Q4. Zener diode ZD3 protects the gate
from overvoltage.
Mosfet Q4 is now switched on
and current can flow from the +340V
supply via the fluorescent tube top
filament, the .001µF 3kV capacitor,
the second tube filament, the 0.1µF
250VAC capacitor, inductor L2 and
transformer T2’s N1 winding. Current
flow in N1 will then apply gate drive
to Q3 via N2 and switch off gate drive
to Q4 via N3 (due to the polarity of the
windings).
If this oscillation does not occur, the
0.1µF capacitor again charges up and
the Diac fires to switch on Q4 again.
Ul
t imately, oscillation will occur
with Q3 and Q4 switching on and off
in alternate fashion. The frequency
of operation is set by the combined
inductance of L2 and the N1 winding
and the .001µF capacitor across fluorescent tube FL1.
The oscillator current now passes
through the fluorescent tube’s filaments and allows the normal mercury
discharge to take place inside the
tube. When this happens, the .001µF
capacitor across the tube is effectively
shunted out by the mercury discharge.
These are the starting pulses present at the drain of Q4
with no tube in circuit. Pulses from Diac1 drive the base
of Q4 and switch it on. Note that a 10:1 probe was used
for this measurement.
This takes place at a peak voltage of
about 100 volts.
The frequency of oscillation is now
determined by the properties of the
core of transformer T2. As the current
builds up in winding N1, the core begins to saturate. When this happens,
the flux in the core stops changing
and the gate drive to Q3 or Q4 ceases.
The flux now collapses to drive the
opposite Mosfet and this process
continues to maintain oscillation.
Current through the tube is limited
by the current at which the T2 core
saturates and the L2 inductance. These
two components provide the same
current limiting function for the tube
as does the ballast in a conventional
fluorescent lamp fitting, except that
the frequency is many times higher
than 50Hz.
The start-up circuit, comprising
the 0.1µF capacitor and Diac1, is
prevented from interfering with
the normal operation of the circuit
by diode D5. The diode discharges
the 0.1µF capacitor every time Q4
is switched on, thus preventing the
Diac from firing.
The gate drive to Q3 and Q4 is
limited using two parallel 330Ω gate
resistors and 12V zener diodes which
clamp the gate voltage to a safe value
for the Mosfets. The 330Ω resistor
from gate to source provides a load
for transformer T2 so that the saturation characteristic for the core can be
accurately set.
Note that while Mosfets Q1 and Q2
in the DC to DC converter are fitted
with heatsinks, Q3 and Q4 switch only
small currents and therefore they do
not require heatsinks. However, during
the switch-over process, when one
Mosfet is switched off and the other
turns on, the Mosfet which is turned
This is the
waveform at the
drain of Q4 when
driving an 18W
tube. The overall
amplitude is 330V
peak to peak &
the frequency is
110kHz.
November 1993 29
12V
off commutates whereby its internal
reverse diode briefly conducts. This
commutation can lead to high dissipation in the Mosfets. To reduce this
dissipa
tion to almost zero we have
connected a snubber network to the
output (ie, the junction of Q3 and
Q4). The snubber network consists
of a 680pF capacitor in series with a
22Ω resistor.
The two 150kΩ resistors connecting from the 680pF capacitor to the
+340V supply act as a load for the
circuit if the fluorescent tube is not
present.
F1
0.1
82
470uF
L1
.001
47k
1M
1k
1k
IC1
TL494
4.7k
0.1
ZD1
1
4.7k
0.1
1
IC2
4050
270k
470uF
T1
GND
TERMINAL
1
470uF
Q1
270k
D1-D4
0.1
250VAC
0.1
150k
680pF
150k
150k
22
ZD3
Q4
330
330
150k
ZD2
Q3
N2
330
T2
N3
330
330
330
N1
0.1
250VAC
L2
F2
1
.001
3kV
TO
TUBE
END
TO
TUBE
END
30 Silicon Chip
Fig.3: the PC board layout. Note that transistors Q1 & Q2 are fitted with heatsinks & note also that high
voltages are present on the board when power is applied.
Q2
ST2
6 F1
S2
F2
S
F 1
10
PRIMARIES: 4T, O.5mm DIA. ENCU
SECONDARY: 136T, 0.4mm DIA ENCU
Fig.4: the winding details for
transformer T1. Note that the
primary windings are bifilar.
Circuit changes
8.2k
0.1
T1
S1 5
There are a few changes to be made
to the circuit, depending on whether it
is to be used with an 18W or 36W fluorescent tube. These are shown in the
table on the circuit. The input fuse (F1)
is 2A or 5A and the winding details of
transformer T2 are varied. The reason
why transformer T2’s windings are
varied is to vary the frequency of the
fluorescent driver circuit and thereby
set the current through the tube.
For 18W tubes the frequency is
110kHz and for 36W tubes the frequency is about 65kHz. While the
frequency for the 36W tube is not
quite halved, the changes to transformer T2, combined with the fixed
inductance of L2, means that the
current is doubled.
High frequency operation
Before concluding the circuit description, we should make a comment
WARNING!
This project develops potentially
lethal voltages. At no time should any
part of the circuit be touched while
power is applied. This project should
not be attempted by inexperienced
constructors.
about operating fluorescent tubes at
high frequencies. In some technical
literature, fluorescent tubes are stated to be much more efficient at high
frequencies. This is not true.
There may be a small difference
between operation at 50Hz and, say,
1kHz but above that, the light output
from a fluorescent tube is directly proportional to the current through it, although there are limiting factors above
which the tube becomes overheated
and its life is shortened. Therefore,
the efficiency of the circuit is much
the same for the 18W and 36W tube
versions of the circuit, regardless of
the fact that the operating frequencies
are different.
Note also that the 18W version of
the circuit will work with a 20W tube
and the 36W version will work with
a 40W tube. The slightly higher rated
(and thicker) tubes have the benefit
that they are easier to start but they
are more expensive.
We should also make some comments about the circuit effi
ciency.
We have set the current through the
respective 18W and 36W fluorescent
tubes to be close to the value it would
be if running in a conventional 50Hz
ballast circuit. This results in the
A piece of blank PC board material is used to prevent direct contact with the
underside of the components board through the large cutouts in the batten base.
The hole for the starter (in the batten cover) should also be sealed.
The assembled PC board fits neatly in one end of the batten, as shown in the
photograph at top. Make sure that the board is properly secured before fitting
the cover & the fluorescent lamp.
18W version of the circuit drawing
1.5 amps from a 12V supply and the
36W version drawing 3 amps from a
12V supply.
Does this make the circuit 100%
efficient? The answer is clearly no
since an 18W fluorescent tube does
not dissipate 18 watts – a significant
amount of power in an 18W fitting is
dissipated by the ballast. Hence, while
we cannot quantify the overall circuit
efficiency, we can state that it is quite
high and certainly higher than other
inverter designs intended for driving
fluorescent tubes. Our estimate of the
efficiency is “better than 80%”.
Construction
The PC board for the circuit is coded
11312931 and measures 286 x 46mm.
It will fit inside a standard 18W or 36W
fluorescent tube batten.
Construction can begin by winding
the toroids and the transformers. Let’s
start with L1, the larger of the two
toroids and brown in colour. Wind on
18 turns of 0.8mm enamelled copper
wire with even spacing around the
toroid.
L2 is not a toroid but is the smaller
ferrite assembly comprising a bobbin,
two core halves and two clips. Before
winding this you will need to set the
gap in the centre leg of the core halves.
You will need a small file (a points or
hobby sized file would be ideal) and
a set of feeler gauges.
Initially, place the two core halves
together and observe that there is no
gap between the mating surfaces of
the core halves. Now file only the
centre leg of one core half, making
sure that you are filing squarely and
evenly across the face. The required
gap is 0.15mm and can be accurately
measured with feeler gauges when the
two halves are held together with your
fingers. The whole process should not
take longer than 5 minutes since the
ferrite material is quite soft.
Now wind 60 turns of 0.4mm enamelled copper wire onto the bobbin,
with the start end soldered to pin
6. Wind each layer neatly side by
side across the bobbin and insulate
between each layer with a length of
insulating tape. Solder the end of the
winding to pin 7 on the bobbin. The
inductor can then be completed by
fitting the core halves into the bobbin
and securing them with the clips.
Transformer T1 is the larger of the
two ferrite assemblies. The ferrite
RESISTOR COLOUR CODES
❏
❏
❏
❏
❏
❏
❏
❏
❏
❏
❏
No.
1
2
4
1
1
2
2
2
1
1
Value
1MΩ
270kΩ
150kΩ
47kΩ
8.2kΩ
4.7kΩ
1kΩ
330Ω
82Ω
22Ω
4-Band Code (1%)
brown black green brown
red violet yellow brown
brown green yellow brown
yellow violet orange brown
grey red red brown
yellow violet red brown
brown black red brown
orange orange brown brown
grey red black brown
red red black brown
5-Band Code (1%)
brown black black yellow brown
red violet black orange brown
brown green black orange brown
yellow violet black red brown
grey red black brown brown
yellow violet black brown brown
brown black black brown brown
orange orange black black brown
grey red black gold brown
red red black gold brown
November 1993 31
Fig.5: this is the PC artwork reduced to 70.7%. To reproduce it full size, use a photocopier with an expansion ratio of 1.41.
cores should not be gapped in this
case since we want the gap to remain
at zero. Fig.4 shows the winding
details. Wind on the secondary first
using 0.4mm enamelled copper wire.
Terminate the start of the winding at
pin 2 and neatly wind on one layer of
wire across the bobbin. Insulate this
with a layer of insulating tape.
32 Silicon Chip
Note here that the start and finish
of the insulating tape should begin on
the underside of the bobbin (ie, the pin
side of the bobbin). This will ensure
that the ferrite core halves will fit over
the completed windings. Continue
wind
ing until 136 turns have been
wound on in several layers with insulation tape over each layer. Terminate
the finish of the winding at pin 1.
The two primary windings are
wound bifilar (ie, two wires at the same
time), with one end of each winding
starting at pins 4 and 5 and finishing
at pins 6 and 7, respectively. Wind on
four turns, making sure that the two
windings do not cross over each other.
Note that there will not be sufficient
room to cover the windings with
insulation tape. These windings can
be clearly seen in one of the photos
accompanying this article.
When the bobbin is completed, fit
the core halves and the retaining clips.
Toroid T2 is wound as detailed in
the table on the circuit diagram (Fig.2).
If you are making the 36W version,
use 0.4mm enamelled copper wire. If
you are making the 18W version, use
0.25mm enamelled copper wire. Wind
on the N1 winding, keeping the windings tightly packed toward one side of
the toroid. The N2 and N3 windings
must be wound in the same direction
as the N1 winding.
With the transformers and inductors
complete, assembly of the PC board
can proceed. Before installing components, check the board for shorts
or breaks in the tracks. Also check the
holes for correct sizing for each component. You will need 3mm holes for
the PC board mounting, transformer
T2 and for the heatsink mounting feet.
Two 3mm holes are also required for
a cable tie to hold down L1.
Start the board assembly by inserting all the PC stakes plus the four
2AG fuse clips. This done, insert the
resistors, links and diodes, followed
by the two ICs. Make sure that the
diodes and ICs are correctly oriented
before soldering. The same comment
applies to the electrolytic capacitors.
The ST2 (Diac1) can be installed either
way around.
Now install transformer T1 and
inductor L1 onto the PC board, taking
care that pin 1 marked on the bobbin
is oriented correctly. Transformer T2 is
mounted using a transistor mounting
bush together with a Nylon screw and
nut. L1 is held in position using a small
plastic cable tie.
Mosfets Q1 and Q2 are fitted with
small vertical heatsinks using machine
screws and nuts. Apply a smear of
heatsink compound to the mating
Below: this close-up view shows
how transformer T2 is secured to
the PC board using a Nylon screw,
a transistor insulating bush & a nut.
Coil L1 at the other end of the board
is secured using a plastic cable tie.
Be sure to install Q3 & Q4 with their
metal tabs adjacent to the edge of the
board.
surfaces before screwing the Mosfet
body to the heatsink. Each heatsink
is secured using the integral mounting
feet which pass through the holes in
the PC board. When they are inserted
into the board, use a pair of pliers to
twist the feet and hence lock them into
the board. This done, solder the Mosfet
leads to the copper pattern. Mosfets
Q3 and Q4 can also be mounted at this
stage – they do not require heatsinks.
Finally, fit the fuses into the fuse
clips and the board is complete.
Installation
We recommend that the PC board
be installed into the fluorescent batten
before testing, because the voltages
developed by the circuit are potentially lethal.
Before installation, the existing
ballast, starter and terminal strip
will need to be removed from the
fluorescent batten. Now drill holes to
accommodate the PC board and drill
out a hole for the cord grip grommet
suitable for the 12V lead entry.
We mounted the board on top of a
piece of blank PC board material to
cover the copper tracks (any other
insulating material would do), while
the hole for the starter was covered
using a piece of plastic and a metal
clip. This will prevent direct contact
with the underside of the PC board
through the large cutouts in the batten
base and cover. The board mounts
onto transistor mounting bushes,
used here as low profile spacers, and
is secured at six points with screws
and nuts.
Connect up a length of polarised
twin-lead to the 12V input and connect
the wires from the tube ends to the PC
board as shown on the wiring diagram.
The negative terminal of the PC board
is connected to chassis using a short
piece of hook-up wire soldered to a
solder lug.
Testing
Once the PC board has been installed in the batten, you are ready for
testing. Insert a fluorescent tube into
the fitting and apply power. The tube
should initially glow with a bluish
tinge for a half second or so and then
come on with full brilliance. There
should be no flicking during the startup phase (as is the case with normal
fluorescent lights) and there should be
no discernible flicker at all once the
tube is at full brilliance.
PARTS LIST
1 PC board, code 11312931, 286
x 46mm
1 blank PC board, 336 x 46mm
1 18W or 36W fluorescent tube
batten
1 EFD25/13/9 3F3 core (no air
gap), former and clips (2 x
Philips 4312 020 4116 1, 1 x
4322 021 3524 1, 2 x 4322 021
3516 1) – T1
1 RCC12.5/7.5/5 3F3 ring core (1 x
Philips 4330 030 3792 1) (T2)
1 RCC17.1/9.8/4.4 2P90 ring core
(1 x Philips 4330 030 6031 2)
–L1
1 EFD20/10/7 3F3 core, former and
clips (2 x Philips 4312 020 4108
1, 1 x 4322 021 3522 1, 2 x 4322
021 3515 1) – L2
2 battery clips (1 red, 1 black)
2 vertical mount TO-220 heatsinks
(Jaycar Cat. HH-8504)
4 2AG PC mount fuse clips
1 5A 2AG fuse (36W version)
1 2A 2AG fuse (18W version)
1 400mA 2AG fuse (36W version)
1 200mA 2AG fuse (18W version)
1 cord grip grommet
7 transistor mounting bushes (6 for
4mm PC board standoffs)
1 3mm Nylon screw and nut
1 small cable tie
2 3mm dia x 6mm long screws &
nuts
8 3mm dia x 12mm long screws,
nuts & washers
1 solder lug
1 80mm length of 0.8mm tinned
copper wire
1 600mm length of 0.8mm
enamelled copper wire
If the inverter does not power up the
fluorescent tube, switch off power immediately and check for faults. Check
that all the components are located
correctly and that the transformers and
inductors are wound and oriented correctly. Transformer T2 must be wound
with correct phasing or the oscillator
will not function.
You can check that the DC-DC converter is functioning by measuring
the voltage between the GND terminal
and F2 fuseholder. It should be 340V
DC. Use your multimeter set to read
1000VDC and check that the multime-
1 10.5m length of 0.4mm
enamelled copper wire
1 500mm length of 0.5mm
enamelled copper wire
1 800mm length of 0.25mm
enamelled copper wire
1 2m length of twin automotive wire
(polarised)
7 PC stakes
Semiconductors
1 TL494 switchmode IC (IC1)
1 4050 CMOS hex buffer (IC2)
2 MTP3055E avalanche protected
N-channel Mosfets (Q1,Q2)
2 BUK455-600A, BUK457-600B
high voltage N-channel Mosfets
(Q3,Q4)
5 1N4936 fast recovery diodes
(D1-D5)
1 ST2 Diac (DIAC1)
1 16V 1W zener diode (ZD1)
2 12V 1W zener diodes (ZD2,
ZD3)
Capacitors
3 470µF 25VW PC electrolytic
2 0.1µF 250VAC metallised
polypropylene
5 0.1µF MKT polyester
1 .001µF MKT polyester
1 .001µF 3kV
1 680pF 3kV
Resistors (0.25W, 1%)
1 1MΩ
2 1kΩ
2 270kΩ
4 330Ω 1W
4 150kΩ
2 330Ω
1 47kΩ
1 82Ω
1 8.2kΩ
1 22Ω
2 4.7kΩ
ter probes are in good condition before
making this measurement. The voltage
is potentially lethal.
Further tests can be made using
an oscilloscope. You must connect
the oscilloscope probe earth connection to the GND terminal on the PC
board. Keep your probe set on 10:1.
You should be able to see the starting
pulses applied to Q4, by measuring
the waveform at the drain (metal tab)
of Q4 when the tube is out of circuit.
The oscillation should be observed at
Q4’s drain when the tube is installed
SC
(see oscilloscope photographs).
November 1993 33
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