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 How A BD679 Works
 
   
 In this issue we have designed a number of projects using a BD679 Darlington
 transistor. This is a very handy transistor with very high gain and high
 current handling capability. It is effectively two transistors in this one
 package and can be used for many applications. In this article we will cover this transistor and how to work with similar
 super-alpha devices.
 
 There are 4 ways to describe how a BD 679 works, they 
 are:
 1. Using conventional current flow,2. Using electron theory,
 3. Using resistance analogy, and
 4. Using the "visual" approach.
 
 We will cover the 4 different ways and let you work out 
 which is the easiest to understand and how they interact with one-another.
 
 Conventional current flow is easier to understand than 
 electron theory while the resistance approach is more closely allied to the 
 beginners level. But the visual approach is the best. By covering the 4
 approaches, everyone will be able to understand the operation.
 The author has used super-alpha (Darlington) devices for the past 20 years, when repairing TV's 
 and equipment, and studied the circuits to find out how they operate in each of
 the applications.
 The visual approach is easiest to understand is an NPN transistor with the emitter connected to the 
 negative rail. This is called a COMMON-EMITTER stage. But it works equally well with PNP transistors as you can 
 visualise them as being an upside-down NPN transistor.
 
  This is how to see it:The BD 679 Darlington transistor is two transistors in one package, connected 
 as shown in the diagram above. The upper transistor is a small-signal 
 transistor and has its collector and base leads coming out of the package. The
 lower transistor has its collector and emitter leads coming out of the package.
 Obviously the collector lead is common to both transistors.
 When a voltage is applied to the base of this Darlington 
 device, a current, flows into the base and turns the top transistor ON.
 Delivering current into the base is exactly the same as lifting the base a small amount 
 with your finger. You don't need very much effort. The base is very easy to 
 lift. This small effort is amplified by the transistor to the emitter and it 
 lifts the emitter with the strength of about 100 times the effort you provided.
 This "pulling-up" effect is now transferred to the base 
 of the power transistor and it is equivalent to raising the base with 100 times
 more force than you exerted on the external base.
 The power transistor inside the device PULLS DOWN very strongly on the bottom
 of the LOAD RESISTOR and this allows a higher voltage to appear across the
 LOAD. The result is the load is activated.
 That's it. You lift the base UP very 
 gently and the Darlington transistor pulls DOWN very strongly on the load 
 resistor.
 
   
   
     
       | INSIDE 
       THE BD 679
 
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       Inside the case of the BD 679 there are two transistors formed on a 
       single silicon substrate, plus two resistors and a protection diode.These components are connected together to form a 
 "circuit" and it is important to know of their existence so that you can use 
 the transistor correctly and understand the effect these components will have 
 when the transistor is placed in a project.
 For instance, the 10k resistor on the base will have an 
 effect on the current required by the base to turn the transistor on. Normally, 
 1uA on the base of a Darlington would turn the transistor on but in our case 
 the 10k base resistor lowers the input impedance (resistance) of the base 
 considerably so that about 1mA is required. In fact, most of the current 
 delivered into the base is lost in the biasing network. That's why we had 
 trouble with one of our projects.
 Normally the transistor is used in a high current section of a circuit and these small losses are not 
 significant.
 |  RESISTANCE ANALOGYNow for the resistance analogy. When no current flows 
 into the base of the transistor, the resistance between the collector and 
 emitter leads is very high. When you allow a small current to enter the 
 base, the resistance between collector and emitter is reduced.
 If you allow more current to pass into the base, the 
 resistance between collector and emitter becomes even lower. For example, when 
 no current flows into the base, the collector-emitter resistance may be 10Meg 
 ohms or more.
 For a small current into the base, the collector-emitter 
 resistance may be 10k. When more current flows into the base, the 
 collector-emitter resistance may be 100 ohms or as low as a few ohms.
 If we have a resistor - called the LOAD RESISTOR - 
 connect to the collector, we create a circuit similar to two resistors in 
 SERIES and current will flow through the load resistor and transistor according 
 to ohms law. As the resistance of the transistor decreases, the current through 
 the pair increases.
 There is nothing special about this, it is simple ohms 
 law, as the transistor turns on harder, the current through the load resistor 
 (and the transistor) increases.
 If the resistance of the transistor decreases to a few ohms, you can see the
 current through the load will be a maximum and the device will be
 activated.
 CONVENTIONAL CURRENT APPROACHThe conventional current approach is the concept that 
 current flows out the positive terminal of a battery and into the negative 
 terminal.
 In our case, when a small current flows into the base of 
 the Darlington transistor, the collector-emitter circuit allows a larger 
 current to flow.
 When more current is allowed to flow into the base, the 
 transistor will allow a greater current to flow in the collector-emitter 
 circuit.
 Since a load resistor is connected to the collector, this 
 collector-emitter current will also flow in the load.
 THE ELECTRON APPROACHThe electron approach basically says that electron flow 
 occurs in the opposite direction to conventional current flow. In other words, 
 electrons flow out the base to the positive rail and others flow in the 
 emitter-collector circuit from the negative rail to the positive rail. The
 electron approach is  necessary if you want to describe the 
 actual operation of transistor itself.
 THE VOLTAGE APPROACHOne final way of looking at the operation of the circuit 
 is the VOLTAGE approach.
 The transistor does not turn on until a voltage of 0.65v + 0.65v  = 1.3v
 is supplied to the base lead.
 This voltage allows a small current to flow into the base and the voltage on
 the collector falls from rail voltage to slightly less than rail voltage. This
 puts a small voltage across the load and a small current flows in the
 load.
 As the voltage on the base is increase a few more millivolts, more current is
 able to flow into the base and the transistor multiplies this flow about 2,500
 times and the increased current is allowed to flow in the collector-emitter
 circuit.
 Increasing the voltage on the base a few more millivolts will allow more
 current to flow into the base (in the order of milliamps) and very soon the
 maximum current will flow via the collector-emitter.
 If the load is a relay or globe, the device will be activated.
 You really need to combine all the concepts we have 
 described to see how the transistor works.
 Once you can see how the collector and emitter leads 
 "squeeze" together or reduce in resistance, to deliver a current to the load, 
 you will be able to see how the transistor works.
 
 As more current is delivered to the load, this will 
 introduce another feature you need to understand. It's called . . .
 TRANSISTOR DISSIPATIONAll the current through the load must flow through the 
 transistor - this is obvious as the two are connected in series, and when 
 current flows, heat is produced.
 Unfortunately, transistors don't like to get hot and so 
 the heating effect must be kept to a minimum.
 When the transistor is off (no base voltage 
 applied) no current flows and thus the heating effect is zero. This is
 obvious.
 This is one of the states of a transistor and is called 
 "cut-off" or simply "off."
 As the transistor gets turned on, more current flows and 
 the heating effect increases.
 Do you think this increase will be a maximum when the 
 transistor is fully turned on?
 No! Amazingly, the heating effect increases until half 
 rail voltage appears on the collector and starts to reduce until it becomes 
 nearly zero when the transistor is fully turned on. This state is called 
 "saturation" or "bottoming."
 This is a very important feature in electronics and means 
 there are two states when the transistor is dissipating the minimum energy 
 (heat) - the two states are: "bottoming" and "cut-off."
 When a transistor is used in digital mode, it switches 
 from one state (say cut-off) to the other (saturation) very quickly and very 
 little heat is generated (lost) in the transistor.
 But when a transistor is used in an audio application, it 
 moves very slowly between one state and the other and a lot of heat is 
 generated.
 This heat must be passed to a heat-sink as quickly as 
 possible to prevent the transistor heating up and self-destructing.
 Self destruction may be final or partial and may produce 
 loss of gain, an open circuit or a "short-circuit." Most often a transistor 
 goes short-circuit.
 
     
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 BD 679 RATINGS 
 
 
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       | MAXIMUM RATINGS: Collector-emitter voltage VCEO = 80v. The maximum voltage 
 between collector and emitter when the transistor is NOT conducting.
 Collector-base voltage VCBO = 80v
 Collector current IC = 4amp. Maximum continuous collector 
 current.
 Collector peak current (t = less than 1mS) = 7 amp.
 Base current IB = 100mA. The maximum current that can be 
 fed into the base of the BD 679 without damaging the transistor. It is not the 
 current required to turn it on fully - much less is required to turn it on 
 fully.
 Junction temperature Tj = 150°C
 Total power dissipation 40 watts. This is the maximum 
 wattage that can be dissipated by the transistor when it is adequately heat-sinked.
 Minimum forward current gain (hFE @1.5amp) = 750
 Typical forward current gain (hFE @1.5amp) = 2500
 Maximum forward current gain (hFE @1.5amp) = 3500
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 GETTING MORE TECHNICAL Let's get a little more technical. One of the problems 
 with the BD 679 is the minimum voltage between the collector-emitter terminals, 
 when the transistor is fully turned on. This minimum voltage is about 2-3v, 
 where as a normal transistor can go as low as .3v. For a MOSFET, the voltage 
 can be .02v or lower.
 Ideally, this voltage should be as low as possible as it 
 determines the heat lost in the transistor when it is fully turned on. For 
 instance, if a BD 679 is passing 4 amps in its saturated mode, the heat lost 
 will be 2 x 4 = 8watts, or in the worst case, 3 x 4 = 12 watts.
 For a MOSFET, the heat loss will be less than 0.08 watts.
 WHY?Why is the minimum collector-emitter voltage of a Darlinglon = 2.5v?
 To see why, we need to see the diagram of the transistor 
 as shown in the figure below:
   
 The small-signal part of the Darlington is riding on top 
 of the power transistor. As the collector of the power transistor falls during 
 turn-on conditions, it pulls the collector of the small-signal transistor down 
 with it and robs it of collector-emitter voltage.This reduces the gain of the small-signal transistor and 
 the collector-emitter current is also reduced so the power transistor will not 
 be able to turn on as hard. This means the voltage on the collector will not 
 fall below 2.5 volts as this leaves only about 2.5v - .65v = 1.85v, for the 
 collector-emitter voltage of the small signal transistor.
 This is just enough to give the transistor a collector 
 voltage so that it can provide some gain to drive the power transistor.
 This is one of the limitations of a Darlington transistor.
 BASE VOLTAGEAnother characteristic of a Darlington transistor is the 
 base voltage. It needs a voltage of 1.3v for the transistor to begin to turn 
 on.
 This compares with .65v for a normal transistor.
 Darlington transistors consist of two transistors in a 
 staircase arrangement and the base voltage is .65v + .65v = 1.3v. See diagram
 below:
   
     
       | The two base-emitter voltages 
       combine to produce 1.3v to turn the Darlington transistor ON. |  PNP DARLINGTON
 By combining two PNP transistors, a PNP Darlington 
 transistor can be created. This is shown below. Matched pairs of PNP and NPN Darlington 
 transistors can also be obtained so that a push-pull output can be created.
 
 PHOTO DARLINGTONOther Darlington devices can also be created. A photo-Darlington transistor is available under the part number MEL-12. This is a 
 very sensitive device for detecting light and can be used for many applications 
 such as photo-electric beams, light detection etc.
 The structure of the MEL-12 is shown below:
   
     
       | MEL-12 Photo Darlington Transistor |  By building and experimenting with some of the projects we have described in this
 e-magazine you will get greater understanding of how a transistor 
 works and how hot it can get before being damaged. To give an example, some of 
 the first colour TV sets had the chrominance output transistors 
 running so hot you could boil water on them. The latest sets use tiny plastic 
 transistors and they run completely cold!  It's all in the way the circuit
 is designed. Circuits should always be designed so that everything runs cold. That 
 way, things last forever.
 
 INSIDE DARLINGTON TRANSISTORS
 The transistors inside the Darlington package can be 
 arranged in a number of different ways. Apart from the NPN and PNP devices, some 
 have resistors in the package while others have no resistors. Some have a 
 reverse protection diode between the collector and emitter terminals and others 
 have protection diodes on the base. Below is a selection of the circuits inside
 Darlington packages.
 The base resistors are designed to prevent the transistor 
 "turning on" due to natural leakage through the small signal transistor.
 These circuits show that Darlington transistors are not 
 all the same and cannot always be replaced with a different type. The different 
 value of base resistor will mean different base currents will be required and 
 you should always replace a device with the same type.
 
  
 
           
 
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