DN05088/D Design Note – DN05088/D Dimmable, 9.5 W, 120 Vac CCR Lighting Circuit Application LED Lighting, AC Input Voltage 110 to 130 Vac Topology Efficiency Input Power Power Factor THD Parallel-toSeries 80% 9.6 W 0.97 18.2% Figure 1 – Evaluation board with heat sink for LEDs. Key Features All the LEDs are equally bright, so LEDs can be distributed apart from each other such as in a T8 tube Dimmable with standard Triac dimmers without wasteful active bleeding Power factor = 0.97 THD below 20% Adjustable for different total LED voltages between 135 and 145 volts by changing a single resistor (R3) Thermal foldback; regulated current decreases as temperature increases Temperature compensated control circuitry Tested and proven from -40 °C to 85 °C in temperature chamber with minimal input power variation June 2016, Rev. 1 www.onsemi.com 1 DN05088/D Schematic Figure 2 – Two-Stage Parallel-to-Series LED Lighting Circuit, with Switch-In CCR. It is possible to mount for an inductor (L1) and an additional capacitor on the board for additional EMI filtering, but generally these are not needed and L1 has a 0 ohm resistor in its place on the evaluation board. C2 may also be populated to ensure compatibility with a small minority of dimmers which require bleeding current even when manually switched off. Circuit Operation This circuit is an enhanced parallel-to-series LED lighting circuit. It uses updated control circuitry that allows the ability to accommodate multiple LED voltages by simply adjusting a single resistor (R3) as well as compensating for drift in LED voltage with temperature. It also has superb PF and THD performance, dimmability, low cost, and efficiency. This circuit uses a parallel-to-series topology that dynamically adjusts LED load voltage as the instantaneous bridge output voltage varies. While a switch-mode power supply such as a buck converter reconfigures the input voltage to match the load, this circuit reconfigures the load to match the input voltage. When the instantaneous input voltage is relatively low, the LEDs are configured in parallel. When the instantaneously input voltage is relatively high, the LEDs are configured in series. The circuit is designed for input voltages between 100 VAC and 140 VAC . ON Semiconductor CCRs are used to provide constant LED current and to protect LEDs from over-voltage conditions. The circuit employs an additional CCR (shown as CCR2) to increase LED current at high voltages for improved efficiency, PF, and THD performance. June 2016, Rev. 1 www.onsemi.com 2 DN05088/D Figure 3 – The LED configuration is dynamically adjusted by the control circuitry. When AC instantaneous voltage is relatively low, the LEDs are configured in parallel. At relatively high AC instantaneous voltages the LEDs run in series. How to Adjust the Driver for Different LEDs For demonstration purposes, this circuit is configured with four LEDs that have a nominal forward voltage of 36 V. The recommended range for the total voltage of all LEDs combined for this type of circuit is 135 to 145 V. This range is approximate but will allow for the best efficiency and dimmability. Use an oscilloscope to probe the voltage across CCR1 and CCRX. CCR1 and CCR3 should run with their anode-cathode voltage (VAK) at 3 to 6 volts as the LEDs switch from parallel-to-series. Make slight adjustments to R3 to accomplish this. For example, the typical value for R3 will be 52.3k, but a certain LED may require 47k for R3. If the CCR1 and CCRX voltage is too high when the strings switch their configuration, the circuit will be less efficient. If CCR1 and CCRX Vak is too low then efficiency will improve but some TRIAC dimmers may misfire. The base-emitter voltage at Q2 initiates the switch from parallel-to-series. This base-emitter voltage is about 0.6 V. The total LED voltage of the six 24 V Cree LEDs in this circuit was about 142 V. R3, R4, D3, and Q2 set the switching point. 𝑅3+𝑅4 ) 𝑅4 𝑉𝑆𝑊𝐼𝑇𝐶𝐻(𝑄2) = VBE(Sat) ( 52.3𝑘+374 ) 374 = 0.6 ( = 85 V The contribution from D3 is about 62 V, and the contribution from R3, R4, and Q2 is about 85 V. Therefore the approximate switching point is 62 + 85 V = 147 V. So to adjust for a lower LED voltage such as 138 V, adjust R3 lower. June 2016, Rev. 1 www.onsemi.com 3 DN05088/D 𝑅3+𝑅4 47𝑘+374 𝑉𝑆𝑊𝐼𝑇𝐶𝐻(𝑄2) = VBE(Sat) ( ) = 0.6 ( ) = 76 V 𝑅4 374 These calculations make assumptions such as a constant and precisely measured LED voltage, so be sure to verify with an oscilloscope that CCR1 has VAK between 3 to 6 V at the switching point. Use Table 1 as a reference for starting values of R3. Please note that higher LED voltages provide better efficiency. Table 1. Suggested starting values for R3 to tune the circuit for different LED voltages. Total LED Voltage for all LEDs in Series 136 V 138 V 140 V 142 V 144 V Suggested starting value for R3 (verify CCR1 Vak with oscilloscope) 47.6 kΩ 48.9 kΩ 50.1 kΩ 51.4 kΩ 52.3 kΩ Also be sure that CCR3 is active just above the switching point. R3 can be manipulated for this purpose if necessary. If CCR3 is on for too long, THD will improve but efficiency will decrease slightly. To tune this, decrease the value of R2 in 5 or 10% increments. If CCR3 is not on for long enough, THD and efficiency will suffer. Increase the value of R2 in 5 or 10% increments to correct this. Figure 4 – When adjusting for different LEDs, choose R3 such that CCR1 has 3 to 6 V across it at the point the red arrow indicates in the figure. This point is where the LEDs switch from parallel to series. While this switch takes place the CCRs must continue conducting so allow for them to have 3 to 6 V. June 2016, Rev. 1 www.onsemi.com 4 DN05088/D Populating L1 and C2 The evaluation board is shipped with L1 shorted as a 0 ohm resistor and C2 populated with an X2 film capacitor. L1 and C2 form an EMI filter. Generally EMI filtering is not needed with these circuits because they are not switching power supplies. Using C2 has several advantages and disadvantages. The advantages are increased EMI filtering and surge protection, but these are not really needed for most applications. Also it ensures compatibility with some dimmers that require a leakage path to maintain the LEDs in the off state when the dimmer’s manual switch is turned off. Another way to provide this leakage is with a resistor, but that would decrease efficiency. We recommend testing with and without C2 and checking whether the circuit satisfies whatever requirements are being sought for a particular lamp. The disadvantages to C2 are the size, cost, and extra population step. Circuit Performance Data (with small heat sink attached to LEDs) June 2016, Rev. 1 Specification 110 VAC 120 VAC 130 VAC IRMS(out) (mA) 58 70 76 Power Factor 0.968 0.975 0.978 THD Total (IRMS, %) 21.7 18.2 15.7 PIN (W) 7.95 9.6 10.9 Efficiency (%) 77.6 80.1 78.2 www.onsemi.com 5 DN05088/D Bill of Materials Designator Quantity Description R1 1 Resistor SMD R2 1 Resistor SMD R3 1 Resistor SMD R4 1 Resistor SMD R5 1 Resistor SMD R6 1 Resistor SMD R7, R8 2 Resistor SMD C1 1 Capacitor SMD C2 1 X2 Film Capacitor BD1 1 Bridge Rectifier Value 510k, 1/8th W 422, 1/8th W 52.3k, 1/8th W 374, 1/8th W 10k, 1/8th W 51k, 1/8th W 100k, 1/8th W 10nF, 500 V 220 nF, 275 VAC 600 V Tolerance Footprint Manufacturer Manufacturer Part Number Substitution Allowed 5% 0805 Any Any Yes 1% 0805 Any Any Yes 1% 0805 Any Any Yes 1% 0805 Any Any Yes 5% 0805 Any Any Yes 5% 0805 Any Any Yes 5% 0805 Any Any Yes 20% 0805 Any Any Yes 10% Through Hole Wurth Electronics Inc 890324023028 Yes N/A TO-269AA Vishay MB6S-E3/80 Yes MMSZ5265BT1G No BAS21HT1G No ON Semiconductor ON Semiconductor D3 1 Diode SMD 62 Vz 5% SOD-123 D4 1 Diode SMD 250 V N/A SOD-323 LED Board D1-D4 4 SMD LED 36V N/A SMD Cree MHBAWT-0000000N0BD265E No Q1 1 N/A N/A SOT-23 ON Semiconductor MMBTA56LT1G No Q2 1 N/A N/A SOT-23 ON Semiconductor MMBT3904LT1G No Q3 1 N/A N/A SOT-23 ON Semiconductor MMBT6517LT1G No Q4 1 N/A N/A SOT-23 ON Semiconductor NSS1C201LT1G No Q5 1 N/A N/A SOT-23 ON Semiconductor NSS1C200LT1G No CCR1 1 120V, 30mA 15% SMB ON Semiconductor NSIC2030JB No CCR2, CCRX 2 120V, 50mA 15% SMB ON Semiconductor NSIC2050JB No F1 1 Fuse SMD N/A 2-SMD Littelfuse 044301.5DR Yes MOV1 1 Varistor SMD N/A 2-SMD Littelfuse V220CH8T Yes L1 1 Resistor SMD NA 0805 Any Any Yes June 2016, Rev. 1 PNP Bipolar Transistor SMD NPN Bipolar Transistor SMD NPN Bipolar Transistor SMD NPN Bipolar Transistor SMD PNP Bipolar Transistor SMD Constant Current Regulator SMD Constant Current Regulator SMD 1.5A, 250V 198V, 250A 0, 1/8th W www.onsemi.com 6 DN05088/D Compatible with Triac Dimmers This circuit is inherently compatible with triac dimmers. The LEDs run for a large portion of time and the sinusoidal current draw resembles that of an incandescent bulb. In the ON Semiconductor lab the circuit was tested with the dimmers below and found to be fully functional. Populate C2 to ensure compatibility with a small minority of dimmers which require bleeding current even when manually switched off. Dimmers Tested Manufacturer Serial Number Lutron DVCL 153P Lutron DVWCL 153P Lutron CTCL 153P Lutron TECL 153P Lutron AYCL 153P Lutron 5LL 153P Lutron LGCL 153P Lutron SCL-153P Lutron MACL 153MH Leviton IPL06-10Z Leviton 6674 - POW Levitron 1B410S Legrand WS703 Legrand DCL453PTC 1 © 2016 ON Semiconductor. Disclaimer: ON Semiconductor is providing this design note “AS IS” and does not assume any liability arising from its use; nor does ON Semiconductor convey any license to its or any third party’s intellectual property rights. This document is provided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associated with its use, including, but not limited to, compliance with all regulatory standards. ON Semiconductor may change any of its products at any time, without notice. Design note created by Andrew Niles, Andrew Stemple, and Cody Campana. June 2016, Rev. 1 www.onsemi.com 7