UM10390 HF-TL ballast with UBA2021 for TLD58W Lamp

UM10390
HF-TL ballast with UBA2021 for TLD58W Lamp
Rev. 01 — 11 October 2009
User manual
Document information
Info
Content
Keywords
UBA2021, HF-TL ballast, TLD58W Lamp
Abstract
A low cost electronic TL ballast has been designed, which is able to drive
a Philips TLD58W lamp or similar.
UM10390
NXP Semiconductors
HF-TL ballast with UBA2021 for TLD58W Lamp
Revision history
Rev
Date
Description
01
20091011
First issue replaces application note AN98099
Contact information
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
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UM10390
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HF-TL ballast with UBA2021 for TLD58W Lamp
1. Introduction
A low cost electronic TL ballast has been designed, which is able to drive a Philips
TLD58W lamp or similar.
A voltage fed half bridge inverter has been chosen as lamp driver circuit. The inverter has
been designed for a nominal input voltage of 230 V (RMS) and 50 Hz to 60 Hz. The key
component in this circuit is the UBA2021 Integrated Circuit (IC) intended to drive and
control a Compact Fluorescent Lamp (CFL) and/or Tubular Lamp (TL). The UBA2021 is a
high voltage driver IC, which provides all the necessary functions for a correct preheat,
ignition, and burn-state operation of the lamp. The UBA2021 also provides the level shift
and drive circuit (high-side driver and bootstrap function included) for the two discrete
power MOSFETs PHX3N50E and incorporates a capacitive mode protection.
The key issues for this design are low cost and low component count. The UBA2021 has
a few peripheral components. Only a minimum amount of components are required for the
optimal balance between maximum design flexibility and low component count.
2. Circuit and system description
2.1 Block diagram
The TL ballast has been designed for a nominal mains voltage of 230 V (RMS),
50 Hz to 60 Hz. The ballast operates within a mains voltage range of
185 V (RMS) to 265 V (RMS) and the mains voltage performance range is limited to
200 V (RMS) to 260 V (RMS). Basically, the circuit consists of three sections, an EMI
filter, an AC bridge rectifier, and the half bridge inverter. Figure 1 shows the block diagram
of the circuit. The complete schematic diagram is given in Figure 3.
Fig 1.
Block diagram
The AC mains voltage is rectified by four bridge rectifying diodes. The DC supply voltage
for the half bridge inverter is smoothed by a buffer capacitor. An EMI filter is used to
minimize the disturbance to the mains. The half bridge inverter is of the voltage fed type
belonging to a group of high frequency resonant inverters, which are very good for driving
lamp circuits. They can achieve a high efficiency because of the zero voltage switching
principle. This reduces the switching losses of the two power MOSFETs.
2.2 Half bridge inverter
For a reliable system operation and long lamp maintenance, the fluorescent lamp is
preheated first after switch on. This is called "warm start". This preheat current is
controlled by the UBA2021, see Figure 2 for the functional diagram. The electrode current
meets the requirements to obtain a proper electrode emitter temperature.
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UM10390
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HF-TL ballast with UBA2021 for TLD58W Lamp
Proper preheating results in a smooth ignition of the lamp at a much lower ignition voltage
with less component and/or electrical stress.
The circuit is designed so that a feed forward control regulates the lamp power. The result
is an almost constant level of light output over a large mains voltage range.
2.3 Start-up phase
After switch-on of the system, the rectified mains voltage is applied to the buffer capacitor
C4 via inrush limiter R1. The buffer capacitor smooths the ripple voltage caused by the
(doubled) mains frequency. The result is a high DC voltage Vhv, which is an input for the
half bridge inverter (power components: TR1, TR2, L1, C7, the lamp, C5, and C6).
During the start-up phase, the low voltage supply capacitors C9, C10, and C13 are
charged out of the high DC voltage via resistors R2, R4, a lamp electrode, and pin 13 of
the UBA2021. Pin 13 is internally connected to pin 5 during the start-up phase (start-up
supply path). As soon as the supply voltage Vs across C13 reaches 5.5 V, the UBA2021
resets. After this initial reset, MOSFET TR2 is set conductive and MOSFET TR1 to
non-conductive. This allows the bootstrap capacitor C12 to be charged via the UBA2021
internal bootstrap function. The supply voltage Vs increases and the circuit starts
oscillating when Vs > 12 V. The IC supply current is internally clamped up to currents of
14 mA. The system now enters the preheat phase.
Remark: The system provides automatic protection against starting up while no lamp is
connected. The start-up supply path is interrupted by the absence of the electrode (see
Section 2.7).
2.4 Preheat phase
The MOSFETs TR1 and TR2 are brought in conduction alternately. This introduces a
square-wave voltage, Vhb, across the half bridge midpoint between zero and Vhv. The start
frequency is 98 kHz. Under these conditions the circuit formed by D5, D6, and C8 through
C10 is able to take over the low voltage supply function from the start-up supply path.
For a time period of approximately 1.8 s (preheat time, tph), defined by capacitor C17 and
R7, the system stays in the preheat operating point where the lamp electrode current is
controlled. This allows both lamp electrodes to heat up in a defined, optimal way. The
electrode emitters are warmed up and large quantities of electrons are emitted into the
lamp. Ignition of the lamp can now take place at a much lower ignition voltage so that the
electrical stress applied to the circuit and the lamp is minimal. This defined electrode
preheat followed by a smooth ignition is very important to obtain a good maintenance of
the lamp.
After the start of oscillation, a small AC current starts floating from the half bridge midpoint
through L1, C7, and the lamp electrodes. The frequency now gradually decreases and the
AC current increases. The slope of decrease in frequency is determined by the value of
capacitor C14 and an internal current source. The frequency decrease stops when a
defined value of the AC voltage across the preheat sense resistors R5 and R6 is reached,
approximately 3 ms after switch-on. The UBA2021 now controls the AC current through
the lamp electrodes by measuring the voltage drop across R5 and R6. This control point is
called preheat operating point. Figure 5, Figure 6, Figure 7, and Figure 8 show some
oscillograms of this controlled preheat.
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UM10390
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HF-TL ballast with UBA2021 for TLD58W Lamp
During the whole preheat phase, the half bridge frequency is well above the resonance
frequency of L1 and C7 (55.6 kHz), so the voltage across C7 is low enough to keep the
lamp from igniting. It is very important to keep the voltage across C7 well below the
non-ignition value of the lamp. Otherwise, the lamp ignites too early which causes
blackening of the lamp ends. This phenomenon is called "cold ignition".
The value of the ballast coil L1 is determined by the required lamp current, the igniter
capacitance C7, and the operating frequency in the burn phase. The value for the
minimum igniter capacitance C7 is determined by L1 and the non-ignition voltage of the
lamp at a given preheat current and a minimum mains voltage. The result is that an igniter
capacitor C7 = 8.2 nF gives the best preheat performance.
2.5 Ignition phase
After the preheat time has expired, the UBA2021 further decreases the switching
frequency of the half bridge down to the bottom frequency fb (39 kHz). Now the rate of the
decrease in frequency is much slower than it was in the preheat phase. The switching
frequency moves towards the resonance frequency of the series circuit formed by L1, C7,
and the lamp electrodes (55.6 kHz), where the impedance of the DC blocking capacitors
C5 and C6 are proposed to be rather small.
The worst case ignition voltage1 of the TLD58W lamp is about 600 V (pk) for low
temperatures. The combination of ballast coil L1 and igniter capacitor C7 has been
chosen in such a way that the voltage across the lamp can exceed this high level. The
ignition voltage of the lamp determines the maximum value of C7 at a given L1 due to the
bottom frequency, fb, of the UBA2021. The bottom frequency is set by R7 and C15/C16.
The maximum available ignition time tign is 1.7 s (15/16 part of tph) set by C17 and R7.
Assuming the lamp has ignited during the downwards frequency sweep, the frequency
decreases to the bottom frequency, fb. The UBA2021 can make the transition to burn
phase in two ways:
• If fb is not reached, the transition is made after the maximum available ignition time,
tign
• when fb is reached
2.6 Burn phase
In the burn phase the circuit normally drops down to fb (39 kHz) which can be used as the
nominal operating frequency. However, the circuit is designed to use the feed forward
control of the UBA2021 so that the frequency is dependent on the current through the
RHV pin (pin 13). The feed forward control becomes active after reaching fb.
During the start-up phase the low voltage supply capacitors C9, C10, and C13 are
charged by the high DC voltage Vhv, via the resistors R2, R4, the lamp electrode, and
pin 13 of the UBA2021. Pin 13 is internally connected to pin 5. In the burn phase previous
interconnection is replaced by another connection, pin 13 to pin 8. Now the current
through R2 and R4 is used as feed forward information to control the switching frequency
of the half bridge and is proportional to the amplitude of the rectified mains voltage Vhv.
1.
When both the luminaire and the circuit are connected to the mains protection earth.
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UM10390
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HF-TL ballast with UBA2021 for TLD58W Lamp
The ripple on Vhv (100 Hz to 120 Hz) is filtered by C17. The effect is that the lamp power
stays more or less the same over an input mains voltage range of
200 V (RMS) to 260 V (RMS) (see Table 3).
The lamp can be seen as a resistive load for frequencies above 10 kHz. The lamp
efficiency of a TL lamp driven at a frequency above 10 kHz increases considerably
compared to a 50 Hz to 60 Hz driven lamp. This means that a TLD58W powered with
50 W HF gives the same light output as a TLD58W lamp powered with 58 W at
50 Hz to 60 Hz. The steady state operating point of a TLD58W lamp is given by a lamp
voltage of 110 V (RMS) and a lamp current of 455 mA RMS) resulting in a lamp power of
50 W.
The value of the ballast coil L1 is determined by the lamp operating point, the igniter
capacitance C7, and the operating frequency which is approximately 45 kHz at a nominal
input of 230 V (RMS).
It can be calculated that for the actual values of L1, C7, and the TLD58W lamp, the total
circuit delivers the desired lamp power. However, other L1/C7 combinations are also
possible. Parameters like the preheat operating point, the minimum required ignition
voltage, and component tolerances determine which combination suits best. The result is
that an inductance of L1 = 1 mH as ballast coil and igniter capacitor C7 = 8.2 nF give the
best overall performance.
2.7 Protections
A capacitive mode protection has been implemented in the UBA2021 IC to protect the
power circuit against excessive electrical stress. This protection will become active during
the ignition phase and the burn phase. Therefore the UBA2021 checks the zero voltage
switching condition each half bridge switching cycle. This is done by monitoring the
voltage across R5 and R6. If this voltage is below 20 mV (typical) at the time of turn-on of
TR2, capacitive mode operation is assumed.
As long as this capacitive mode is detected, the UBA2021 IC increases the switching
frequency. The rate of frequency increase is much faster than the rate of decrease during
the preheat phase and the ignition phase. Finally, the switching frequency will be above
the resonance frequency. If no capacitive mode is detected, the frequency drops down
again to the feed forward frequency.
A lamp removal protection is incorporated by means of the low voltage supply for the
UBA2021. When lamp removal takes place, the AC voltage on C6 is zero so that the low
voltage supply for the UBA2021 is cut off. The circuit starts up when the lamp is replaced
without switching off the ballast.
Finally, the circuit will not start up when the lamp is not present. In this situation, the
start-up resistor R4 is cut off from Vhv.
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HF-TL ballast with UBA2021 for TLD58W Lamp
2.8 Power components
The used electrolytic capacitor C4 is of the ASH-ELB 043 series, especially designed for
electronic lamp ballasts, with a useful life time of 15.000 hours at 85 °C and a high ripple
current capability.
The applied MOSFETs, TR1 and TR2, are of the type PHX3N50E22. Due to the Zero
Voltage Switching (ZVS) principle, the switching losses of the two power MOSFETs are
reduced to a minimum. The power losses are merely conduction losses that heat up the
devices that are dependent on their thermal resistance, Rth, and drain-source resistance
RDson. The duration of the preheat phase and the ignition phase is rather small so that the
choice of the MOSFET type is determined by the ballast coil current in the burn phase.
The PHX3N50E is supplied in the SOT186A full pack, isolated package. The PHX3N50E
characteristics are: VDSS = 500 V and RDson < 3 W. All together the PHX3N50E suits best
in this application.
The ballast coil, L1, of 1 mH is designed to withstand ignition peak currents of up to 2.5 A
so that a system without protection earth can be used. The used coil is an E25/13/7 -core
with 3C85 as core material.
The ignition capacitor, C7, of 8.2 nF is of the KP/MMKP 376 type designed for applications
where high dV/dt with a high repetition rate is desired. The applied capacitor withstands
peak-to-peak voltages of up to 1700 V (600 V (RMS) sine wave).
2.9 UBA2021
2.9.1 General
The control component is the UBA2021 IC. This is a high voltage IC intended to drive and
control a Compact Fluorescent Lamp (CFL) and/or Tubular Lamp (TL). The UBA2021
contains a driver circuit with integrated high-side drive and bootstrap function, an
oscillator, and a control and timer circuit for starting up, preheating, ignition, lamp burning,
and capacitive mode protection. The maximum voltage applied to the IC is 390 V and for
short transients (t < 0.5 s) 570 V. The low voltage supply is internally clamped so that an
external zener diode is not needed. The current clamp capability is 14 mA and for short
transients (t < 0.5 s) 35 mA. The UBA2021 is available in the DIP14 package and the
SO14 package.
Figure 2 shows the functional diagram of the UBA2021.
2.
The suffix “E” means that the MOSFET is a repetitive ruggedness rated device.
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HF-TL ballast with UBA2021 for TLD58W Lamp
Fig 2.
UBA2021 functional diagram
2.9.2 Design equations UBA2021
Equation 1, Equation 2, Equation 3, Equation 4, Equation 5, and Equation 6 give the
design calculations for the UBA2021. The typical UBA2021 parameters3 are listed in
Table 1.
Table 1.
UBA2021 typical parameters
X1 = 3.68
Rint = 3 kΩ
X2 = 22.28
Cpar = 4.7 pF
τ = 0.4 μs
Vref = 2.5 V
The bottom frequency, fb, is set by Rref and Cf. In the circuit diagram Rref = R7 and
Cf = C15//C16.
1
f b = ---------------------------------------------------------------------------------------------2 ⋅ [ ( C f + C par ) ⋅ ( X 1 ⋅ R ref – R int ) + τ ]
(1)
The feed forward frequency fff depends on the current through the RHV pin, IRHV.
Equation 2 calculates the feed forward frequency fff which holds for the interval
0.5 mA ≤ IRHV ≤ 1 mA. The frequency is clamped for currents out of range.
1
f ff = ------------------------------------------------------------------------------------------------V ref
2 ⋅ ( C f + C par ) ⋅ ⎛ X 2 ⋅ ---------- – R int⎞⎠ + τ
⎝
I RHV
(2)
The preheat time tph is set by Rref and Cp. In the circuit diagram is Rref = R7 and Cp = C17.
3.
The UBA2021 data sheet gives a detailed description.
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HF-TL ballast with UBA2021 for TLD58W Lamp
Cp
R ref
- ⋅ ------------------t ph = ------------------------–9
3
150 × 10
30 × 10
(3)
The ignition time tign is a factor of tpre.
15
t ign = ------ ⋅ t ph
16
(4)
The non-overlap time tno is given by Equation 5 (Rref = R7).
t no = 1.4 × 10
–6
R ref
⋅ -------------------330 × 10
(5)
The operating frequency, foper, is the maximum value of fb, fff, and fcm, where fcm is the
frequency due to the capacitive mode operation.
f oper = max ( f b , f ff , f cm )
(6)
3. HF-TL BALLAST PCB
The 58 W TL ballast with UBA2021 is designed on printed-circuit board using leaded
components. In this chapter the schematic diagram, layout, and parts list are given.
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Schematic diagram ballast
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HF-TL ballast with UBA2021 for TLD58W Lamp
Rev. 01 — 11 October 2009
Fig 3.
NXP Semiconductors
UM10390_1
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3.1 Schematic diagram ballast
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Component side and copper side
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HF-TL ballast with UBA2021 for TLD58W Lamp
Rev. 01 — 11 October 2009
Fig 4.
NXP Semiconductors
UM10390_1
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3.2 Layout ballast
UM10390
NXP Semiconductors
HF-TL ballast with UBA2021 for TLD58W Lamp
3.3 Bill of materials ballast
Table 2.
Bill of materials ballast
Part
Value
Rating
Type
12 no. code
C1
220 nF
275 V
MKP 336 2
2222-336-20224
C2,C3
2.2 nF
250 V
MKP 336 6
2222-336-60222
C4
33 μF
450 V
ASH 043
2222-043-91339
C5, C6
47 nF
250 V
MKP 379
2222-379-44473
C7
8.2 nF
2000 V
KP/MMKP 376
2222-376-92822
C8
15 nF
250 V
MKT 370
2222-370-35153
C9, C10, C13
1 μF
63 V
MKT 370
2222-370-75105
C11
1 nF
630 V
KT 347
2222-347-61102
C12, C14
100 nF
63 V
MKT 370
2222-370-75104
C15
10 pF
100 V
Class I; 2 %; NPO 2222-680-10109
C16
100 pF
100 V
Class I; 2 %; NPO 2222-680-10101
C17
270 nF
63 V
MKT 370
2222-370-75274
R1
4.7 Ω
-
AC04
2322-329-04478
R2, R4
220 kΩ
350 V
SFR25H
2322-186-16224
R3
470 kΩ
350 V
SFR25H
2322-186-16474
R5, R6
1.2 Ω
350 V
SFR25H
2322-186-16128
R7
30.1 kΩ
350 V
MRS25
2322-156-13013
L1
1 mH
-
EF25/13/7
8228-001-32932
T1
27 mH
-
CU15d3/1
3112-338-31712
IC1
UBA2021
-
SOT27
available on
request
D1 to D4
BYW54
-
SOD57
9333-636-10153
D5, D6
1N4148
-
SOD27 (DO-35)
9330-839-90153
TR1, TR2
PHX3N50E
-
SOT186A
9340-550-03127
F1
1 A Slow
-
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HF-TL ballast with UBA2021 for TLD58W Lamp
4. Performance
4.1 Oscillograms
Fig 5.
Lamp voltage and lamp current delayed with 1.3 s
Fig 6.
Lamp voltage and lamp current zoomed at ignition
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Fig 7.
Ballast coil current delayed with 1.3 s
Fig 8.
Ballast coil current zoomed at ignition
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HF-TL ballast with UBA2021 for TLD58W Lamp
4.2 Ballast performance
Table 3.
Ballast performance
Vmains (V)
Pmains (W)
Plamp (W)
η (%)
200
52.0
47.6
92
210
53.5
48.9
91
220
54.4
49.6
91
230
55.0
50.0
91
240
55.4
50.2
91
250
55.6
50.3
91
260
55.8
50.3
90
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5. Legal information
5.1
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.
5.2
Suitability for use — NXP Semiconductors products are not designed,
authorized or warranted to be suitable for use in medical, military, aircraft,
space or life support equipment, nor in applications where failure or
malfunction of a 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.
Disclaimers
General — 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.
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.
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.
5.3
Trademarks
Notice: All referenced brands, product names, service names and trademarks
are the property of their respective owners.
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6. Contents
1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.9.1
2.9.2
3
3.1
3.2
3.3
4
4.1
4.2
5
5.1
5.2
5.3
6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circuit and system description . . . . . . . . . . . . 3
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Half bridge inverter . . . . . . . . . . . . . . . . . . . . . . 3
Start-up phase . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preheat phase . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ignition phase . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Burn phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power components . . . . . . . . . . . . . . . . . . . . . . 7
UBA2021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Design equations UBA2021 . . . . . . . . . . . . . . . 8
HF-TL BALLAST PCB . . . . . . . . . . . . . . . . . . . . 9
Schematic diagram ballast . . . . . . . . . . . . . . . 10
Layout ballast . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bill of materials ballast . . . . . . . . . . . . . . . . . . 12
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oscillograms . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ballast performance . . . . . . . . . . . . . . . . . . . . 15
Legal information. . . . . . . . . . . . . . . . . . . . . . . 16
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Please be aware that important notices concerning this document and the product(s)
described herein, have been included in section ‘Legal information’.
© NXP B.V. 2009.
All rights reserved.
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
Date of release: 11 October 2009
Document identifier: UM10390_1