Application Note AN-1171 IRPLLED7 90-250VAC Offline LED Driver using IRS2980 ife By Peter B. Green O fL Table of Contents En d Page 1. Introduction ......................................................................................2 2. Constant Current Control .................................................................3 3. High Voltage Regulator ....................................................................5 4. Current Sense Level Shifter .............................................................5 5. PWM Dimming .................................................................................6 6. IRPLLED7 Circuit Schematic ...........................................................7 7. Bill of Materials.................................................................................8 8. PCB Layout ......................................................................................9 9. Test Results .....................................................................................10 10. Design Procedure Summary ..........................................................13 Safety Warning! The IRPLLED7 LED driver does not provide safety isolation. When operating the output drive to the LEDs can produce potentially dangerous voltages. This board is intended for evaluation purposes only and should be handled by qualified electrical engineers only! www.irf.com AN-1171 1 ife EVALUATION BOARD - IRPLLED7 1. Introduction En d O fL Solid state light sources are now available that offer viable alternatives to Fluorescent and HID lamps and far surpass incandescent lamps. Luminous efficacy expressed in Lumens per Watt has now reached levels enabling LEDs to be used for general illumination. High brightness LEDs also possess the added advantages of longer operating life span up to 50000 hours and greater robustness than other less efficient light sources making them suitable for outside applications such as street lighting. High power LEDs are ideally driven with constant regulated DC current, requiring a "driver" or "converter" to provide the required current from an AC or DC power source. A simple single stage power converter based around the IRS2980 LED driver IC provides a controlled current output over a wide AC line or DC voltage input range. The IRPLLED7 evaluation board is an off line non-isolated constant current Buck regulator LED driver designed to supply a 350mA DC output current. The LED output voltage can be up to 90% of the input voltage, operating from an AC line input voltage between 90 and 250VAC 50/60Hz or 50 to 300VDC. It also includes PWM dimming capability from 10% to 100% of light output controlled by an on board potentiometer. Important Safety Information The IRPLLED7 does not provide galvanic isolation of the LED drive output from the line input. Therefore if the system is supplied directly from a non-isolated input, an electrical shock hazard exists at the LED outputs and these should not be touched during operation. Although the output voltage is low this electrical shock hazard still exists. It is recommended that for laboratory evaluation that the IRPLLED7 board be used with an isolated AC or DC input supply. The IRS2980 series Buck topology www.irf.com AN-1171 2 ife is suitable only for final applications where isolation is either not necessary or provided elsewhere in the system. Figure 1: IRPLLED7 Block Diagram O fL 2. Constant current control En d The IRS2980 is a hysteretic Buck controller operating in continuous conduction mode (CCM) and using a low side switching MOSFET as the controlled switch and a fast recovery diode as the uncontrolled switch connected to the positive DC bus. This mode of operation is opposite to the IRS25401 and includes a differential floating high side current sense circuit, which is used to hysteretically control the output current by sensing the voltage drop across a sense resistor and regulating the average to 0.5V. The IRS2980 is designed for use in current regulated circuits and not voltage regulated circuits. Figure 2: IRS2980 Basic Schematic www.irf.com AN-1171 3 Figure 2 illustrates how the current is sensed by differentially measuring the voltage between the HV and CS inputs, RF and CF have been added to provide noise filtering. When the MOSFET (MBUCK) is switched on the current in the inductor LBUCK rises linearly according to the relationship: Vin − Vout = Lbuck . di dt di dt O fL Vout = − Lbuck . ife Where Vin is the bus voltage rectified from the AC line voltage and Vout is the combined series voltage of the string of LEDs making up the load. When the voltage at HV rises to 0.55V with respect to CS the gate drive to MBUCK switches off. When the MBUCK is off the inductor current flows instead through DBUCK. During this period the current decreases linearly according to the relationship: VCS RCS En Iout (avg ) = d When the voltage at HV falls to 0.45V with respect to CS the gate drive to MBUCK switches on. The cycle repeats continuously to provide an average current in LBUCK which supplies the LED load. The frequency and duty cycle are dependent on the input and output voltages and the value of the LBUCK as can be inferred from the equations. The output current can be set by selecting the appropriate value of RCS according to the relationship: where VCS is 0.5V, therefore for an RCS of 1.5V, the output current will be nominally 333mA. In practice there are some additional propagation delays in the circuit which give rise to a small variation in the current regulation over input voltage, however the accuracy adequate for LED applications. Accuracy of regulation and amplitude of the current ripple are tradeoffs against inductor size. The IRS2980 incorporates a frequency limiting function that prevents the frequency from exceeding approximately 150kHz. This is necessary in order to limit the VCC current consumption since the internal high voltage regulator can supply only a limited current (ICC) which is dominated by gate drive current. Gate current charges and discharges the MOSFET gate capacitance during each switching cycle and therefore increases with frequency. www.irf.com AN-1171 4 3. High Voltage Regulator O fL ife The IRS2980 contains an internal high voltage regulator to supply VCC from the high voltage DC bus. Figure 2 shows that pin 1 (HV) is connected directly the DC bus. Current is supplied to the VCC supply at pin 2 through an internal current source capable of operating up to 450V. The internal regulator can supply up to 3mA, which is sufficient to supply VCC for most MOSFET gate capacitances and frequencies normally required in an LED driver. ICC can be reduced by selecting a MOSFET with a low gate capacitance (25nC or less) and selecting an inductance (LBUCK) that will allow the regulator to operate at a reduced frequency. A regulator operating at 60kHz for example will require much less ICC than one operating at 120kHz. As explained earlier this is a tradeoff against inductor size. It is also important to consider the temperature rise of the IRS2980. Since the internal regulator operates linearly the associated power loss is dependent on bus voltage and ICC. More care must be taken at higher bus voltages to minimize frequency and ICC to minimize the IC operating temperature. The addition of heat sinking in the form of large areas of copper on the PCB or thermally conductive potting compounds can significantly reduce temperature. Inductor values are generally larger for 220V off line AC applications than for 120V in order to reduce switching frequency, which lowers power dissipation in the circuit. 4. Current sense level shifter En d The IRS2980 uses a floating differential current sense circuit to measure the LED current in the high side of the supply circuit. The Buck regulator configuration uses a low side switch, which is opposite to the IRS25401. In order to realize average current control the current must be sensed both when the MOSFET (MBUCK) is switched on and when it is switched off and therefore must be sensed at the high side. In order to accomplish this the hysteretic current sensing circuitry within the IRS2980 is situated within a floating high side well constructed by means of International Rectifiers HVIC technology. A floating supply voltage (nominally 8V) for the circuitry contained within this well is developed between the HV and VS pins of the IC. The supply is provided by a current source located between VS and COM. The high side contains a comparator with defined hysteresis connected to a -0.5V reference with respect to HV. The output from the comparator is transferred through high voltage level shift circuitry to the gate driver circuitry, which is referenced to COM. The incorporation of the floating high side well allows the LED current to be sensed at voltages up to 450V above COM. www.irf.com AN-1171 5 5. Dimming En d O fL ife The IRS2980 includes a PWM dimming oscillator that provides a linear ramp waveform at the RAMP pin with the frequency determined by an external capacitor to COM (CRAMP). The IRPLLED7 demo board uses a passive valley fill circuit comprising two electrolytic capacitors, three diodes and one resistor to provide a high power factor between 0.8 and 0.9 depending on line voltage and load, without the additional cost of an additional active stage. This circuit (C2,C5,D2,D3,D4 and R3) can be seen in the schematic shown in section 6. The passive valley fill circuit however, creates a high ripple on the DC bus at twice the line frequency (50-60Hz). The constant current Buck regulator is easily capable of compensating for this, however in PWM dimming designs it means that the PWM frequency needs to be significantly higher than 120Hz in order to avoid visible flicker of the LEDs. The PWM dimming frequency in the IRPLLED7 demo board is approximately 800Hz determined by a CRAMP value of 10nF. The dimming ramp varies between 0 and 2V and is compared with a DC dimming control voltage from 0 to 2V applied to the ADIM input at pin 5. The IRPLLED7 board includes a pot which adjusts the ADIM input over the 0 to 2V range to provide the full range of dimming. Figure 3: IRPLLED7 PWM Dimming Figure 3 shows the output current to the LED load at a dimming level of about 30%. It can be seen that the amount of current ripple varies slightly due to the DC bus voltage created by the passive valley fill circuit. At this PWM frequency there is no noticeable flicker during dimming. The IRS2980 is designed for PWM dimming. It can also be used in a linear dimming mode with the addition of a few components. www.irf.com AN-1171 6 1 VAC2 10 / 1W R1 C1 100nF / 250V 1mH / 0.5A L1 2 3 4 1 AN-1171 D4 S1G-13F 22uF / 160V C2 1 + BR1 DF10S C5 22uF/160V S1G-13F D3 R3 10 / 1W + d D2 S1G-13F En C3 C6 0.1uF 0.22uF / 500V R7 5K R4 15K 3 2 OUT CS ADIM RAMP 5 6 7 8 C4 1nF 1.5 / 1W C9 0.1uF 10 R5 MURS120-13 D1 R2 ife VCC VS IC1 IRS2980 O fL C8 22nF 1 HV COM www.irf.com 4 VAC1 C7 0.01uF R6 1K M1 IRFR812 1mH / 0.5A L2 1 1 VOUT- VOUT+ 6. IRPLLED7 Circuit Schematic Figure 4: IRPLLED7 Complete Schematic 7 7. Bill of Materials Item Description Part Number Manufacurer Quantity Reference IC, LED Controller IRS2980S International Rectifier 1 IC1 2 Rectifier ,1A , 400V, SMA S1G-13-F Diodes Inc 3 D2,D3,D4 3 Diode, 1A, 600V, 35nS, SMB MURHS160T3G On Semiconduct or 1 D1 DF10S Fairchild 1 BR1 IRFR812 International Rectifier 1 M1 B32520A3104K Epcos 1 C1 TDK 1 C4 C3216X7R1H104 K TDK 2 C6, C9 EEU-EB2E220 Panasonic 2 C2, C5 TDK 1 C3 TDK 1 C8 TDK 1 C7 ERJ-1TYJ1R5U Panasonic 1 R2 PR01000101009 JR500 Vishay 2 R1, R3 ERJ-8GEYJ153V Panasonic 1 R4 ERJ-8GEYJ100V Panasonic 1 R5 ERJ-8GEYJ102V Panasonic 1 R6 3386P-1-502LF Bourns Inc 1 R7 B82477G4105M Epcos 2 L1, L2 5009 Keystone 2 5005 Keystone 1 5006 Keystone 1 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 C32160G2J102J O fL 6 CKG32KX7T2W2 24M CGA5C2C0G1H2 23J C3216C0G1H10 3J d 5 Bridge, 1000V, 1.5A, 4SDIP MOSFET, 500V, 2.2Ohm, DPAK Capacitor, 100nF, 250V, Radial Capacitor, 1nF, 630V, 10%, 1206 Capacitor, 0.1uF, 50V, 10%, 1206 Capacitor, 22uF, 250VDC, 20% Capacitor, 0.22uF, 450VDC, 1210 Capacitor, 22nF, 50V, 1206 Capacitor, 0.01uF, 50V, 1206 Resistor, 1.5Ohm, 1W, 5%, 2512 Resistor, 10Ohm, 1W, 5%, Axial Resistor, 15K, 0.25W, 5%, 1206 Resistor, 10, 0.25W, 5%, 1206 Resistor, 1K, 0.25W, 5%, 1206 Pot, 5K, 0.5W, Single, Top adjust Inductor, 1mH, 0.55A, 1.68Ohm Test point, 0.063"D Yellow Test point, 0.063"D Red Test point, 0.063"D Black PCB En 4 ife 1 www.irf.com IRPLLED7 Rev C AN-1171 1 8 ife 8. PCB Layout Top Copper En d O fL Top Overlay Bottom Overlay Bottom Copper Layout Considerations It is very important when laying out the PCB for the IRS2980 based LED driver to consider the following points: 1. CVCC (C6) and CHVS (C8) must be as close to IC1 as possible. 2. The feedback path should be kept to a minimum length and separated as much as possible from high frequency switching traces to minimize noise at the CS input. 3. The current sense filter components RF (R6) and CF (C4) should be located close to the IRS2980 with short direct traces. 4. It is essential that all signal and power grounds should be kept separated from each other to prevent noise from entering the control environment. Signal and power grounds should be connected together at one point only, www.irf.com AN-1171 9 which must be at the COM pin of the IRS2980. The IRS2980 may not operate in a stable manner if these guidelines are not followed! All low side components associated with the IC should be connected to the IC signal ground (COM) with the shortest path possible. 5. All traces carrying the load current need to be sized accordingly. 6. Gate drive traces should also be kept to a minimum length. 9. Test Results Measurements were carried out using a variable DC power supply and a load of 7 white LEDs being driven at a nominal 350mA. Ripple (mApp) Frequency Duty (kHz) Cycle (%) ife Output Current (mAav) 335 340 344 349 353 357 360 364 367 370 373 375 377 120 140 150 160 180 190 190 200 200 210 220 230 240 O fL Output Voltage (V) 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 d DC Input Current (A) 0.14 0.12 0.11 0.10 0.09 0.08 0.07 0.07 0.07 0.06 0.06 0.06 0.05 En DC Input Voltage (V) 60 70 80 90 100 110 120 130 140 150 160 170 180 98 99 99 97 95 94 92 89 87 85 83 81 80 40 36 30 26 23 21 19 17.6 16.2 15.2 14.2 13.4 12.6 Table 1: IRPLLED7 Test Results As expected table 1 indicates that the duty cycle is approximately equal to Vout/Vin, the LED total voltage drop divided by the supply voltage. It can be seen that the current ripple increases as the duty cycle reduces since the voltage difference is increasing. This is because: Vin − Vout = Lbuck . di dt and therefore di/dt is increasing, which results in more overshoot in the hysteretic comparator due to inevitable propagation delays in the system. These delays actually provide an advantage because the operating frequency is decreasing with higher input voltage which limits ICC and switching losses in both MBUCK (M1) and DBUCK (D1). www.irf.com AN-1171 10 The gate drive and output current waveforms are displayed in Figure 5: Input = 180VDC ife Input = 60VDC Green Trace = Gate Drive, Blue Trace = Output Current O fL Figure 5: IRPLLED7 Typical Waveforms En d The IRPLLED7 board uses an inductor of 1mA. Increasing this value would reduce frequency and ripple. Ripple can also be reduced by adding a capacitor to the output although this is not necessary in most applications and may reduce the PWM dimming range. In the example shown in figure 6 below, where a load of fewer series LEDs was attached: Yellow = Gate, Green = LED Current Vin = 60V, Iin = 0.09A, Pin = 5.4W Vout = 13.87, Iout = 0.338A, Pout = 4.66W Figure 6: IRPLLED7 at lighter load www.irf.com AN-1171 11 In the following example, an combination of LEDs was connected with a combined voltage drop of approximately 30V. The board is capable of operating down to 60VDC input, below which the high voltage regulator does not operate. In applications requiring a lower input voltage VCC can be supplied directly from an alternate source, the simplest option being a resistor from the DC bus to VCC. Output Current (mAav) 334 330 329 329 331 332 335 337 340 343 346 349 353 Ripple (mApp) Frequency (kHz) Duty Cycle (%) 100 110 120 130 140 150 150 160 170 170 170 170 170 150 154 155 155 157 157 158 159 159 160 160 161 161 54.4 46 41.8 37.3 33.0 30.3 27.4 25.2 25 23.1 21.6 20.5 19.6 ife 60 70 80 90 100 110 120 130 140 150 160 170 180 Output Voltage (V) 30.76 30.60 30.55 30.52 30.43 30.43 30.43 30.43 30.44 30.45 30.47 30.49 30.51 O fL DC Bus Voltage (V) Table 2: IRPLLED7 Additional Test Results En d Since the IRS2980 incorporates an internal high voltage regulator and level shifting circuitry it dissipates some heat during operation which increases with frequency and line voltage. It is necessary as with the MOSFET (MBUCK) and diode (DBUCK) to ensure that these components do not overheat in the application. This is done by providing additional copper around the components on the PCB to allow heat conduction from the devices. In 220VAC off line applications is is necessary to use a suffliciently large inductor (LBUCK) in order to maintain a low operating frequency in the 30 to 60kHz range. This will substantially reduce heat dissipation in all of the components mentioned. Replacing the the 1mH inductor used in the IRPLLED7 demo board with a 3.3mH part lowers the frequency and reduces heat loss in at 200VAC. Efficiency varies depending on input voltage, output voltage, output current and switching frequency. www.irf.com AN-1171 12 10. Design Procedure Summary En d O fL ife 1. Determine the systems requirements: input/output voltage and current needed 2. Calculate current sense resistor 3. Determine the operating frequency required. 4. Select LBUCK so that they maintain supply into the load during t_HO_on. 5. Select the switching MOSFET and diode) to minimize gate drive current and switching losses. IR WORLD HEADQUARTERS: 101 N. Sepulveda Blvd., El Segundo, California 90245 Tel: (310) 252-7105 Data and specifications subject to change without notice. 7/31/2012 www.irf.com AN-1171 13