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University of Portland School of Engineering 5000 N. Willamette Blvd. Portland, OR 97203-5798 Phone 503 943 7314 Fax 503 943 7316 Functional Specifications Project Surf Scoter: Fluorescent Lamp Electronic Ballast Contributors: McGuire, Lance Nelson, Sam Ortiz, Sam Stone, Jordan Approvals Name √ Dr. Ward Mr. Fant Date Name √ Date Dr. Hoffbeck Insert checkmark (√) next to name when approved. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE II Revision History Rev. 0.9 0.95 0.96 1.0 Date 09/21/07 09/28/07 10/03/07 10/05/07 UNIVERSITY OF PORTLAND Author J. Stone J. Stone L. McGuire J. Stone Reason for Changes Initial draft Second draft Third draft Final Revision SCHOOL OF ENGINEERING CONTACT: J. STONE . . . . . Table of Contents . . Summary....................................................................................................................... 1 . . Introduction .................................................................................................................. 2 FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE III Background .................................................................................................................. 3 Requirements ............................................................................................................... 4 Overview ..................................................................................................................................................4 Physical Specifications............................................................................................................................4 General .............................................................................................................................................4 Design Structure...............................................................................................................................5 Weight ...............................................................................................................................................5 Wiring ................................................................................................................................................5 Dimensions .......................................................................................................................................5 Environmental Specifications .................................................................................................................5 General .............................................................................................................................................5 Temperature .....................................................................................................................................5 Relative Humidity .............................................................................................................................6 Altitude ..............................................................................................................................................6 Hardware Specifications .........................................................................................................................6 System Hardware ............................................................................................................................6 Power Supply ............................................................................................................................6 Peripheral Devices ....................................................................................................................6 Cables........................................................................................................................................7 Output Power ............................................................................................................................7 Circuit Board ..............................................................................................................................7 Board Hardware ...............................................................................................................................7 EMI Filter ...................................................................................................................................7 UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE . . . . Rectifier......................................................................................................................................7 . . PFC ............................................................................................................................................7 . . Inverter ....................................................................................................................................... 7 . FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE IV Microcontroller ...........................................................................................................................8 Conclusions ................................................................................................................. 9 UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE . . . . List of Figures. . Figure 1. Block Diagram of.Surf Scoter Product...........................................................................................3 . . FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER UNIVERSITY OF PORTLAND REV. 1.0 SCHOOL OF ENGINEERING PAGE V CONTACT: J. STONE . . . . List of Tables . . . ....................................................................................................................4 Table 1. Physical Specifications . Table 2. Environmental Specifications ..........................................................................................................5 . FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE VI Table 3. System Hardware Specifications ....................................................................................................6 UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER Chapter 1 . . . . . . . . . REV. 1.0 PAGE 1 Summary The goal of Surf Scoter is to design and build an electronic ballast for a fluorescent tube light. Fluorescent lights are much more efficient than traditional incandescent lights, as they consume about ten times less power. Incandescent lights waste energy by converting more of their consumed power into heat, while fluorescents achieve higher efficiency by converting a greater percentage of consumed power into light. The challenge concerning a fluorescent tube lamps is the higher voltage and frequency required to achieve high efficiency. While incandescent bulbs operate at a standard residential voltage and frequency of 120V and 60Hz, respectively, fluorescent lights operating at maximum efficiency require voltages between 200 and 300V and frequencies ranging in the tens of kHz. An electronic ballast must be used to regulate the electricity delivered to the lamp because of these constraints. A ballast is a device that controls the voltage, current and optionally frequency of power driving a lamp. An electronic ballast uses solid-state electronic circuitry to achieve the necessary conditions. This document is a functional specification of an electronic ballast. It provides numerical goals for parameters of the project and a basic outline of the components of which the ballast circuit will consist. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER Chapter 2 . . . . . . . . . REV. 1.0 PAGE 2 Introduction This document is intended for the faculty and senior Electrical Engineering students of the School of Engineering at the University of Portland, as well as the industry representative overseeing this project. A general introduction to fluorescent lamps and electronic ballasts is first presented in this document, followed by a detailed description of the functionality of the electronic ballast which will be designed and built. The basic blocks of circuitry that will be required are also outlined. Not contained in this document are the details of the circuitry or the connections to be made between the components of this product, as these elements have not yet been designed. In some areas, however, possible options for circuit design are given. The rest of this document contains a background of fluorescent lamps and electronic ballasts, an overview and the physical, environmental, hardware and software specifications of the project. This document ends with a conclusion. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER Chapter 3 . . . . . . . . . REV. 1.0 PAGE 3 Background An electronic ballast is an apparatus that controls the current flow into a circuit. In this case, the circuit is a fluorescent lamp. There are various types of ballasts, but the electronic ballast increases the input frequency (typically 60 Hz in the United States) to a much higher frequency in the range of 10 to 40 kHz. Not only does this eliminate the flickering that is typical of fluorescent lighting but also increases the efficiency of the lamp. An electronic ballast can be as simple as a resistor and inductor, but the ballast that will be used here will be made of more complicated solid-state devices. The type of electronic ballast that will be used works by increasing the frequency and amplitude of the input voltage for the initial ionization of the gas within the lamp. Once the arc inside the lamp is started, the amplitude of the input voltage is decreased to a nonzero constant value to maintain the arc. The electronic circuitry that will be used can be broken up into several functional blocks, as shown in Figure 1. First, the standard 120V, 60Hz line power will enter an electromagnetic interference filter. A rectifier then converts the AC signal into DC and a Power Factor Correction (PFC) element will eliminate any reactive power consumption introduced by the circuit or lamp. Next, an inverter will convert the DC power into AC power of the desired voltage, current and frequency to operate the lamp. This inverter will be controlled by a microcontroller to achieve the desired output power. The circuitry in this product will be contained in a case incorporating a safety-switch so that the input voltage cannot be applied unless the case is closed, making the circuitry inaccessible to any humans. The fluorescent lamp itself will also be encased so that particles or chemicals will not cause harm should the circuit or tube malfunction during testing. Fuse EMI Filter Rectifier/PFC Inverter Lamp 120V, 60Hz Microcontroller Figure 1. Block Diagram of Surf Scoter Product UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER Chapter 4 . . . . . . . . . REV. 1.0 PAGE 4 Requirements Overview This product converts single phase, 120V, 60Hz electricity into a signal that can be used to power a fluorescent lamp. Any electricity customer, whether illuminating their residence or business, will benefit from the high efficiency of fluorescent lights, but will require additional components (such as this ballast) for these lights to achieve a high level of efficiency. Power from a 120V, 60Hz, single phase line will enter the circuitry of this product. After passing through the ballast, power will be at a frequency of approximately 20kHz and a voltage between 200 and 300V, depending on the performance of the lamp. Internally, this product will contain solid-state electronic circuitry and a microcontroller. The functional blocks of this circuitry is shown in Figure 1 and discussed in the “Hardware” section of this chapter. Physical Specifications Table 1 contains a list of the physical specifications and their required values. Table 1. Physical Specifications Requirement Value Design Structure Plexiglass box Weight Wiring <10 lb. (ballast only) Leads color coded to ANSI standard Dimensions 5 ft x 1ft x 1 ft General The entire project, including lamp and lamp housing, will be enclosed in a Plexiglass box to ensure that no particle or chemical component of the lamp would injure a person should the lamp malfunction. Additionally, this container will open and close on a hinge and will incorporate a safety-switch that will disengage power when the container is opened, ensuring safety from electrocution. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE . . . . Design Structure . . for the project will be made of Plexiglass, a transparent substance stronger The enclosure . than glass. .It is also impact and electrically resistant to a high degree, in case of an electrical problem or rupture in the lamp. The casing will also help prevent mercury . contamination should the lamp break. FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE 5 Weight The electronic ballast itself will weigh no more than ten pounds. Wiring The electrical wiring of project Surf Scoter will conform to ANSI standards. Dimensions Project Surf Scoter will be contained in a Plexiglass box with a volume of 5ft x 1ft x 1ft. This includes the ballast, lamp and lamp housing. Environmental Specifications Table 2 contains a list of the environmental specifications and their required values. Table 2. Environmental Specifications Requirement General Value Temperature Standard Room Operation 10-40 degrees C Relative Humidity No condensation Altitude 0-8000 ft. General Ballast should be able to operate in a room at standard room temperature with little condensation from relative humidity. Temperature Ballast should withstand standard temperature of 10 to 40 degrees Celsius. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE . . . . Relative Humidity . . not be required to operate in conditions where there is condensation or The ballast will . high relative humidity. . . Altitude FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE 6 The circuit should be operable at up to 8000 feet in altitude. Hardware Specifications This section covers the power supply and hardware specification for project Surf Scoter. The hardware is the nexus of the project. The lamp will only turn on if the hardware is properly designed and configured. These are the specifications for the hardware that define the standards used in designing the electronic ballast. Table 3. System Hardware Specifications Requirement Power Supply Peripheral Devices Cables Output Power Circuit Board Value 120V @ 60Hz 4’ T8 Lamp Luminaire Input power Output power Capable of lighting the lamp High Quality System Hardware Power Supply The ballast design will require an AC supply of 120V at 60Hz, single phase, as provided by a standard electrical outlet. Peripheral Devices A single fluorescent lamp will be operated by the ballast. The model that will be used is a four foot T8 lamp, which is commonly used in commercial applications. The lamp will be supported by a luminaire purchased from a manufacturer or retailer. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE . . . . Cables . . The ballast and lamp will require a cable to deliver the input power from an electrical outlet . to the circuit and another cable to deliver the output power from the ballast to the lamp. . . Output Power FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE 7 The power provided by the ballast will be sufficient to light the lamp used in the project. This includes the appropriate starting conditions and the conditions necessary for long term operation of the lamp. Circuit Board A high quality circuit board will be used for this project, ideally with the internal ballast connections being soldered into place. This board will minimize unintended resistances and capacitances across the circuit. Board Hardware The project will use a standard PC (printed circuit) board, single-sided for lowest cost. EMI Filter The electromagnetic interference (EMI) filter is used to block ballast-generated noise from being transmitted back onto the power lines. This filter may be active or passive, and will be designed according to needs as this project is developed. Rectifier The full-wave rectifier converts the AC source to a DC voltage supply. The rectifier for this project will likely utilize four diodes and a capacitor in a bridge formation. The rectifier will need to be able to handle the input of 120V at 60Hz and convert it to a steady DC source. It will also need input and output impedances controlled to not interfere with the overall operation of the circuit. PFC This unit is used to correct for low power factor present in the input power and introduced by the EMI filter. Depending on the quality of power (ratio of reactive power to real power) this could involve the use of simple capacitors or more complex elements such as Buck, Boost, or Buck-Boost converters. Power Factor Correction can be implemented before or after rectification and whichever order is found to be more efficient will be used. Inverter The inverter converts DC to AC at the desired frequency in order to control the voltage across the fluorescent lamp’s electrodes. This project will utilize solid state circuitry for this UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE . . . . component. This element will need to output the necessary voltage and frequency with . duty cycle controlled by the microcontroller. . . Microcontroller . . will be used to adjust the output frequency to achieve maximum power A microcontroller FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER REV. 1.0 PAGE 8 efficiency and light output from the lamp. This is done via pulse-width modulation control of the inverter. The microcontroller will need to be powered via a DC-to-DC converter to meet the smaller voltages required by the microcontroller. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE FUNCTIONAL SPECIFICATIONS PROJECT SURF SCOTER Chapter 5 . . . . . . . . . REV. 1.0 PAGE 9 Conclusions This document has covered requirements of the electronic ballast design. It has presented the physical makeup of the project and also the environment in which it will be expected to perform. This document also discussed the electronic parts of which the project will be comprised. This document has presented the requirements that will be achieved in developing this project. UNIVERSITY OF PORTLAND SCHOOL OF ENGINEERING CONTACT: J. STONE