AND8433/D Using ON Semiconductor Constant Current Regulator (CCR) Devices in AC Applications http://onsemi.com APPLICATION NOTE Introduction The rectified AC waveform is similar to a pulsed signal. The regulating current will change as the power dissipation changes. The purpose of this paper is to explore the utilization in AC lighting applications with 110 V, and 220 V AC rms input for CCR devices Figure 1. An AC output from a Full Wave Bridge rectifier produces a varying dc voltage which has a value with time of: Vi = Vpk sin(2pft). The value for 2pf is 377 for a 60 Hz waveform and 314 for a 50 Hz waveform. As the voltage is rising across the series configuration of CCR device and LED string it will reach the forward voltage of the LED string ( Vf x Number of LEDs). At this point, the LED string voltage will begin to remain constant. About 1.8 V beyond this LED turn on point, the CCR will turn on to maintain a constant current through the LEDs. The voltage across the CCR will be the difference between the total LED Vf and the Vi up to Vpk. This process reverses on the falling side of the rectified voltage. The effect is to have a PWM (Pulse Width Modulation) of the LEDs at 120 Hz for a 60 Hz waveform or 100 Hz for a 50 Hz waveform. Using a 30 mA steady state CCR in a 120 V AC application results in 22 mA rms due to pulsed operation from full wave bridge rectification. This paper describes applications from new to retrofit circuit designs. The operating range of the CCR in AC circuits is from 1.8 V to 120 V. See appendix B for terms used in AC analysis. The LED on time will depend on the forward voltage drop of the LED string. In the circuits referenced in this application, the CCR on time is about half the peak voltage on time. Thus the LEDs are on for about 50% of the time. The rms current through the LEDs is therefore about 50% of the regulating current. This update includes additional information on 220 V ac lighting circuits with the addition of ON Semiconductors 120 V breakdown family of CCRs. LEDs for AC and DC lighting pose a challenge to lighting designers. Technology for High Brightness (HB) LEDs is rapidly advancing. There are several existing solutions to drive these devices: Switching power devices (buck, boost, and buck-boost), linear regulators and resistor bias circuits. Each has its merits and drawbacks. One thing is common to all. LEDs need to be driven by a constant current source for maximum efficiency (lumens per watt), color and lifetime. Switching regulator topology can be costly, cause EMI, and require additional circuit elements. Linear regulator circuits are less costly; but, may require additional components and are less efficient. Resistor bias is the least expensive method to set a current for a specific voltage. The drawback is that the current changes with a change in input voltage. ON Semiconductor has developed a family of cost effective Constant Current Regulators (CCR) that will simplify circuit design while meeting the consensus requirement to keep the LED under a constant current condition. The CCR can be represented as a variable resistor. As the voltage increases across the device, the internal resistance of the CCR increases to maintain a current close to the specification (Ireg). The CCR also has a negative temperature coefficient, thus as power is dissipated by the CCR (increased temperature), its internal resistance increases causing a reduction in current. The CCR has a higher regulating current when pulsed compared to that at a steady state DC current because the die has not reached thermal stability. 110V 220V AC Full Wave Bridge CCR LED’s Figure 1. Basic AC Application © Semiconductor Components Industries, LLC, 2011 October, 2011 − Rev. 1 1 Publication Order Number: AND8433/D AND8433/D 38 Series LEDs for 110V 80 Series LEDs for 220V Full Wave Bridge Rectifier Series Resistor (if required) Current Sense Resistor CCR 1 CCR 2 Figure 2. Demonstration PCB used for 110 V & 220 V AC rms analysis http://onsemi.com 2 AND8433/D DESIGN EXAMPLE 1: New Design with a CCR Analysis for Vin = -10% (min) Testing for minimum Vin: (110 Vrms – 10%) = 100 Vrms Rectified Vpeak = 100 Vrms x 1.414 = 141 V (peak Vin) CCR Vak is: 141 V (peak Vin) – 125 V (VF LED string) = 16 V The Vak range will vary with the number of LEDs in the string. Adding 3 additional LEDs will set the Vak range from 6 V to 35 V. The additional HB LEDs provides greater luminosity and reduces CCR thermals. This design selects the number of series LEDs. Design parameters: 110 VAC rms, +/- 10%, HB LEDs (VF of 3.3 V at 20 mA). Analysis for Vin = +10% (max) To calculate the number of LEDs for Vin Maximum = (110 V rms + 10%) = 120 V rms Rectified Vpeak = 120 V rms x 1.414 = 170 V VF of LED string = 170 V (peak Vin) – 45 V (Vak max) = 125 V (VF led string) # of LEDs = 125 V / 3.3 V = 38 LEDs TP 1 TP 2 Series resistor Rs (if required) AC 110 V RMS +/- 10% TP 3 30 mA TP 6 SW1 TP 1-6= AC Line in TP 2-5= Bridge Output TP 3-4= Current Sense TP 4-5= LED String Current Sense Resistor Rsense TP 4 TP 5 38 LEDs 3.3 V 3.3 V 3.3 V 3.3 V 3.3 V 3.3 V Figure 3. Direct AC Line LED Circuit with CCR A SOT-223 with a 100 mm2 1 oz Cu heat spreader will operate up to 85°C. The data sheet power dissipation tables show various combinations for other ambient temperatures. The following oscilloscope traces (Figures 4, 5 and 6) are for a 110 V ±10% AC rms input with 38 LEDs in series. The regulated current is measured by using a 100 W, 1% sense resistor. The measurements show the rms voltage across the sense resistor with the rms current below the voltage measurement. The circuit is similar to Figure 3 using a single NSI45030AZT1G 30 mA CCR. The heatsink for the CCR on this test PCB is 500 mm2. All waveforms were taken using differential voltage probes. The AC rms voltage is full wave rectified into pulsating DC at a frequency of 120 Hz. The CCR turns on when the voltage exceeds the VF for the LEDs and the bridge rectifier, controlling the current and isolating the LEDs from the peak rectified voltage. Thermal Analysis of Design Example 1 (120 VAC, 38 LEDs) The power dissipation of the CCR for Figure 3 is determined by: (Vak rms) x (IREG * Duty Cycle ) Vak rms = Vbridge rms - LED string VF rms (120 Vbr rms-(38 x 3.3 V LED x 0.707 ) x (30 mA x 50%) = 31 V rms x 15 mA = 465 mW http://onsemi.com 3 AND8433/D Bridge Output TP 2 - 5 LED String TP 4 - 5 CCR Current TP 3 - 4 Figure 4. 100 V rms 1 x 30 mA CCR Analysis Bridge Output TP 2 - 5 LED String TP 4 - 5 CCR Current TP 3 - 4 Figure 5. 120 V rms, 1 x 30 mA CCR Analysis http://onsemi.com 4 AND8433/D The LED intensity is increased when the supplied current is doubled. The LED VF increases by less than 10% with a 100% increase in drive current. CCRs can be operated in parallel to increase the regulated current supplied to the circuit. The waveforms of Figure 6 were taken with two 30 mA CCRs operated in parallel (Figure 3, SW 1 closed). Bridge Output TP 2 - 5 LED String TP 4 - 5 CCR Current TP 3 - 4 Figure 6. 120 V rms, 2 x 30 mA CCR Analysis In summary for 110 VAC operation: Table 1 Vin AC V rms V rectified V Peak CCRs CCR Ireg mA rms VF LED String VPeak Vak CCR VPeak 100 141 1 CCR 18 123 18 110 156 1 CCR 21 124 32 120 170 1 CCR 24 124 46 120 170 2 CCRs 43 135 34 http://onsemi.com 5 AND8433/D 220 V AC ANALYSIS The following oscilloscope traces were taken on a similar circuit to Figure 3 operating at 220 V AC rms with 80 LEDs in series: All that is required to use a CCR at 220 V AC rms are additional LEDs. Bridge Output TP 2 - 5 LED String TP 4 - 5 CCR Current TP 3 - 4 Figure 7. 220 V rms, 1 x 30 mA CCR Analysis The following oscilloscope traces were taken on a similar circuit to Figure 3 operating at 220 V AC rms ± 10% with 68 LEDs in series using a 120 V, 50 mA CCR device: Figure 8. 198 V rms, 1 x 50 mA CCR Analysis http://onsemi.com 6 AND8433/D Figure 9. 242 V rms, 1 x 50 mA CCR Analysis This CCR is mounted on a 1000 mm2, 3 oz Cu, FR4 heat spreader will operate up to TA of 50°C for a TJ of 175°C. Adding additional LEDs will reduce the power dissipation of the CCR and allow for a higher TA operation. The data sheet power dissipation tables show various combinations for other ambient temperatures. All waveforms were taken using differential voltage probes. Thermal Analysis of Design Example Figure 9 (242 VAC, 68 LEDs) The power dissipation of the CCR for Figure 3 is determined by: (Vak rms) x (IREG RMS) Vak rms = 57.7 V , Irms = 38 mA (from screenshot Figure 9) 57.7 V x 38 mA = 2.19 W http://onsemi.com 7 AND8433/D DESIGN EXAMPLE 2: Retrofitting using a CCR (Figure 10) V drop of Rs = 170 V – (79.2 V + 45 V + 4) = 41.8 V CCR pk current is 34 mA; therefore, Rs = 41.8 V / .034 A = 1229 W (circuit tested with 1200 W RS) The power dissipation is V x I = 1.42 W pk or 1.0 W RMS. Testing for minimum Vin: 110 V rms x 0.9 = 100 V rms using a 1200 W Rs Rectified Vpeak = 100 Vrms x 1.414 = 141 V CCR Vak is 141 V – (79.2 + 41.8 +4) = 16 V Design parameters: 110 V AC rms, +/- 10%, existing design using 24 LEDs (VF of 3.3 V at 22 mA) A series dropping resistor (Rs) will be chosen to keep the CCR within its operating limits. Rectified Vpeak (maximum) = 120 V rms x 1.414 = 170 V VF of LED string = 24 x 3.3 V = 79.2 V The voltage drop required is: Vpeak – (VF leds pk + Vak CCR pk +VRsense pk) TP 1 TP 2 Series resistor Rs AC 110 V RMS +/- 10% TP 3 30 mA TP 6 Current Sense Resistor Rsense TP 1-6= AC Line in TP 2-5= Bridge Output TP 3-4= Current Sense TP 4-5= LED String TP 4 TP 5 24 LEDs 3.3 V 3.3 V 3.3 V 3.3 V 3.3 V 3.3 V Figure 10. Direct AC Line LED Circuit with CCR http://onsemi.com 8 AND8433/D 24 LEDS, 1200W Rs, 1 CCR, 100 W Rsense, 255C TDS5104B Oscilloscope Measurements Max rms Max rms Bridge output 141 98 VLEDs 80 64 VRs+Vak+VRsense 61 34 VRsense 3.6 2.1 VRs+Vak 57.4 31.9 Vak 15.6 6.5 VRs 41.8 25.4 VRs 41.8 25.4 Bridge output 155 107 VLEDs 80.8 65 VRs+Vak+VRsense 74.2 42 VRsense 3.9 2.4 VRs+Vak 70.3 39.6 Vak 26.3 11.6 VRs 44 28 VRs 44 28 Bridge output 171 117 VLEDs 81.7 65.6 VRs+Vak+VRsense 89.3 51.4 VRsense 3.9 2.8 VRs+Vak 85.4 48.6 Vak 39 18 VRs 46.4 30.6 VRs 46.4 30.6 Actual 24 LED, 1200W series resistor circuit measurements Power Dissipation for 120V AC rms Max rms Ireg A 0.039 0.028 PD Rs (W) 0.8568 PD CCR (W) 0.504 PD Rsense (W) 0.0784 PD LEDs (W) 1.8368 Total PD (W) 3.276 Summary The CCR can be represented as a variable resistor. As the voltage increases across the device the internal resistance of the CCR increases to maintain a current close to the specification (Ireg). The CCR also has a negative temperature coefficient, thus as power is dissipated by the CCR (increased temperature) the internal resistance is increased causing a reduction in current. This prevents thermal runaway and protects the LEDs increasing their life and reliability. The CCR has a higher regulating current when pulsed compared to that at a steady state DC current because the die has not reached thermal stability. The rectified AC waveform is similar to a pulsed signal, the regulating current will change as the power dissipation changes. The LED on time will depend on the forward voltage of the LED string. In the circuits referenced in this application it is about half the peak voltage and thus the LEDs are on for about 50% of the time. The rms current through the LEDs is therefore about 50% of the regulating current. See Appendix C for Application Notes, Design Notes and Technical Demonstration list. http://onsemi.com 9 AND8433/D Appendix A: Vpeak = Highest Vin with a sinusoidal voltage (Vin x 1.414) Vbridge rms = Vpeak x 0.707 VF rms = VF LED x 0.707 Rs = series dropping resistor if required. Rsense = series resistor to measure current. V measured / 100 W, 1% resistor = current Ireg = regulated circuit current Ireg rms = Ireg peak x duty cycle (approximately 50%). Reference to Data Sheet: The data sheet describes the devices and defines the following terms that will be used throughout this note: Vak = Voltage applied between the Anode and Cathode of the device. PD = Device power dissipation, typically in W. TA = Ambient Temperature in °C TJ = Device Junction Temperature in °C SOD-123 devices are: NSI45015WT1G, Steady State IREG = 15 mA±20% NSI45020T1G, Steady State IREG = 20 mA±15% NSI45025T1G, Steady State IREG = 25 mA±15% NSI45030T1G, Steady State IREG = 30 mA±15% NSI45020AT1G, Steady State IREG = 20 mA±10% NSI45025AT1G, Steady State IREG = 25 mA±10% NSI45030AT1G, Steady State IREG = 30 mA±10% NSI50010YT1G, Steady State IREG = 10 mA±30% SOT-223 devices are: NSI45025ZT1G, Steady State IREG = 25 mA±15% NSI45030ZT1G, Steady State IREG = 30 mA±15% NSI45025AZT1G, Steady State IREG = 25 mA±10% NSI45030AZT1G, Steady State IREG = 30 mA±10 NSI45020JZT1G, Adjustable IREG = 20−40 mA±15% NSI45035JZT1G, Adjustable IREG = 35−70 mA±15% Appendix C: AND8349/D Automotive Applications: The Use of Discrete Constant Current Regulators (CCR) For CHMSL Lighting AND8492/D Capacitive Drop Drive Topology with Constant Current Regulator to Drive LEDs AND8220/D How To Use Thermal Data Found in Data Sheets AND9008/D Thermal Considerations for Discrete Constant Current Regulators in DPAK, SMC and SMB Packages for Driving LEDs AND8391/D Thermal Considerations for the ON Semiconductor Family of Discrete Constant Regulators (CCR) for Driving LEDs in Automotive Applications DN05013/D NSI45090JD: ENERGY STARR Compliant LED Driver Retrofit in T5 Tube Using 160 mA Constant Current Regulator DN05021/D High Efficiency - Low Cost LED Dimming DN05022/D ENERGY STARR Compliant - Low Cost LED Dimming TND402/D Constant Current Regulator Driver for T8 Fluorescent Light TND403/D Constant Current Regulator Solutions for Driving LEDs DPAK devices are: NSI45060JDT4G, Adjustable IREG = 60−100 mA±15% NSI45090JDT4G, Adjustable IREG = 90−160 mA±15% NSI50350ADT4G, Steady State IREG = 350 mA±10% SMC devices are: NSI50350AST1G, Steady State IREG = 350 mA±10% SMB devices are: NSIC2050BT3G, Vak max = 120V, Steady State IREG = 50 mA±15% (Product Preview) NSIC2030BT3G, Vak max = 120V, Steady State IREG = 30 mA±15% (Product Preview) NSIC2020BT3G, Vak max = 120V, Steady State IREG = 20 mA±15% (Product Preview) SC-74 devices are: NSI45019JPT1G, Adjustable IREG = 19-35 mA±15%, PWM enhanced (Product Preview) Appendix B: For AC (Alternating Current) analysis of series LED circuits, we will be using the following terms: Vin = The input AC Line voltage applied expressed as rms or Stepped down with a transformer. 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