CCRACGEVB An AC LED Lighting Evaluation Board Using Constant Current Regulators (CCR) Evaluation Board User's Manual www.onsemi.com EVAL BOARD USER’S MANUAL Six Different Circuit Topologies Covering Smallest Bill of Materials to Widest Input Voltage: 12 VAC to 250 VAC. Introduction The CCRACGEVB (see Figure 1) has an input voltage range of 12 VAC to 250 VAC and showcases the NSIC20x0JBT3G series of 120 V CCRs and the NSI50150ADT4G (150 – 350 mA Adjustable) CCR. It has circuit topologies for “Straight LED Driving”, “Capacitive Drop LED Driving” and “Chopper LED Driving”, all with and without dimming by typical triac dimmers. It has a simple current inrush limiting circuit to suppress the impact of initial high inrush currents and power spikes. Engineers developing solid-state lighting control systems need to balance circuit efficiency, power factor (PF), total harmonic distortion (THD), total cost of bill of materials (BOM) and input voltage range to cover large geographic regions and aesthetics to satisfy different customer requirements. The CCRACGEVB allows engineers to evaluate six different topologies as they approach this difficult balancing act. AC Input CCRs Cap Drop Input Bridge Inrush Current Limiter Dimmer circuit for Straight Chopper Dimmer circuit for Chopper and Cap Figure 1. CCR AC Evaluation Board − CCRACGEVB © Semiconductor Components Industries, LLC, 2015 February, 2015 − Rev. 1 1 Publication Order Number: EVBUM2176/D CCRACGEVB CCRACGEVB Features: The CCRACGEVB is set up with multiple jumpers to allow reuse of circuit components in the different topologies. There are test points at all the major nodes to enable the collection of circuit performance data and also allow engineers to insert their own components for circuit variations. The components for CCRACGEVB were selected to allow evaluation over a large input voltage range. Designers should review their specific application requirements and determine if smaller or lower cost parts could be selected in place of those used here. The application note is broken up into sections covering the different circuits. A brief circuit description for each topology will be provided with the jumpers selected together with data collected at multiple voltages. Input Voltage • 12 VAC to 250 VAC CCRs • • • • NSIC2020JBT3G 120 V NSIC2030JBT3G 120 V NSIC2050JBT3G 120 V NSI50150ADT4G 50 V 20 mA 30 mA 50 mA 150−350 mA SMB SMB SMB DPAK Topologies • Straight • Cap−Drop • Chopper No Dimming, With Output Capacitance, With Triac Dimming No Dimming, With Triac Dimming No Dimming, With Triac Dimming Inrush Current Limiter LED Board (supplied with CCRACGEVB) • 10x XLAMP MX−6S LEDs Figure 2. Straight Non−dimmable LED Driver (120 VAC example) Straight LED Driver, Non−dimming (120 VAC Example): VF- Total LEDs The Straight LED driver circuit is the simplest with the lowest BOM and highest PF. To setup the CCRACGEVB for the Straight LED driver non-dimming topology, place jumpers according to Table 1. The maximum forward voltage drop across the LED string is determined by the minimum input peak voltage minus the minimum regulating voltage for the CCR. Assuming −10% tolerance of AC mains: MAXV F*Total LEDs + AC Vin MINPeak*V AKMIN Table 1. JUMPERS PLACED ONTO THE EVB Jumpers in Place Reference Data J1, J13, J18, J19, J20, J22, J26 Appendix A MAXV F*Total LEDs + 120 V (eq. 1) 1.414(*10%)*3 V + + 150 V The minimum forward voltage drop across the LED string is determined by the maximum input peak voltage minus the breakdown voltage of the CCR. Assuming +10% tolerance of AC mains: The AC input is rectified using an AC bridge (D1 – D4). A CCR (CCR3, 4, 5 or 6) controls the current through the LED string. The LEDs will be turned on at double the AC mains frequency (120 Hz in the USA). The duty cycle is about 60%. Figure 2 depicts the schematic with the evaluation board reference designators. MINV F*Total LEDs + AC Vin MAXPeak*V AKMAX MINV F*Total LEDs + 120 V + 67 V www.onsemi.com 2 (eq. 2) 1.414()10%)*120 V + CCRACGEVB Conduction Time (TON) Straight LED Driver, Non−dimming, with Output Capacitor (120 VAC Example): The conduction time (on time) of the LED string is based on the VF−TotalLEDs. The rectified voltage needs to rise above the forward voltage of the LEDs before they begin to conduct and the CCR regulates the current through them. The TON conduction time (%) calculation for the typical 120 VAC is the following: ƪ ǒ 1 V F*TotalLEDs T ON(%) + 100 1* 2 sin *1 p ACVin TYPPeak Ǔƫ This circuit will have a higher efficiency compared to the straight LED driver. To set up the CCRACGEVB for the Straight LED driver non-dimming topology with output Capacitor, place jumpers according to Table 2. Figure 3 depicts the schematic with the evaluation board reference designators. Table 2. JUMPERS PLACED ONTO THE EVB (eq. 3) When using 5 x Cree XLamp MX-6S in series providing a VF−TotalLEDs = 100 V, conduction time equals: ƪ ǒ Ǔƫ + 62.3% 100 V 1 T ON(%) + 100 1* 2 sin *1 p 120 V 1.414 Reference Data J1, J10, J13, J18, J19, J20, J22, J26 Appendix B The AC input is rectified using an AC bridge (D1 – D4) and charges the capacitor (C7 & C8 in series). The voltage on the capacitor will be equal to or a little below the peak rectified voltage. A CCR (CCR3, 4, 5 or 6) controls the current through the LED string. The charge on the capacitor allows the CCR to continue providing current to the LED string when the rectified AC voltage is below the VF−TotalLEDs. The Inrush current limiter (T1, R2 & C6) can be employed to limit the inrush current or current spike from a power surge. As the capacitor C6 charges, T1 will turn on and provide a low impedance bypass. Design Trade−off • The lower the VF−TotalLEDs: ♦ Higher %TON conduction time , more light output Lower efficiency due to higher power lost across CCR The higher the VF−TotalLEDs: ♦ Higher efficiency due to less power lost across CCR ♦ Lower %TON conduction time, less light output ♦ • Jumpers in Place Figure 3. Straight Non−dimmable LED Driver with Output Capacitor (120 VAC example) Straight LED Driver, with Triac Dimming (120 VAC Example): This circuit comprises R3 – R7, R17, CCR1, M1, Q1 and D8. The selection of R3/4 and the value of R7 are based on the Triac dimmer. The selection of R3 & R4 in parallel (5.0 KW) and R7 & R17 in series (50 W) have produced good results. This circuit incorporates an additional circuit to provide a minimum load for the Triac dimmer. To set up the CCRACGEVB for the Straight LED driver dimming topology, place jumpers according to Table 3. Figure 4 depicts the schematic with the evaluation board reference designators. Table 3. JUMPERS PLACED ONTO THE EVB Jumpers in Place Reference Data J1, J7, J13, J15, J16, J18, J20, J22, J26 Appendix C www.onsemi.com 3 CCRACGEVB Figure 4. Straight Dimmable LED Driver (120 VAC example) Inrush Current Limiter Cap−Drop LED Driver Topology, Non−dimming (120 & 230 VAC Example): The Inrush Current Limiter (Figure 5) is incorporated to reduce the surge current if power is connected at the peak of the AC input. At turn on, the 6.8 KW resistor will limit the current as the Darlington MJB5742 will be off and the 33 mF capacitor will appear as a short. As the capacitor charges the Darlington will turn on and provide a low impedance bypass. The Cap-Drop circuit is selected for high efficiency and a low BOM cost. To set up the CCRACGEVB for the Cap-Drop LED driver non-dimming topology, place jumpers according to Table 4. Figure 6 & Figure 7 depict the schematics with the evaluation board reference designators. Appendix D shows the 120 VAC example and Appendix E provides its 230 VAC counterpart. Table 4. JUMPERS PLACED ONTO THE EVB Jumpers in Place Reference Data J2, J13, J19, J20, J25, J22, J26 Appendix D (120 VAC) J2, J13, J19, J20, J22, J24 Appendix E (230 VAC) Figure 5. Inrush Current Limiter The operation of the Cap-Drop circuit is very similar to the straight LED circuit with the advantage of improved efficiency because the AC voltage is reduced to be a little over the forward voltage of the LED string. www.onsemi.com 4 CCRACGEVB Figure 6. Cap−Drop LED Driver, Non−dimming (120 VAC example) Figure 7. Cap−Drop LED Driver, Non−dimming (230 VAC example) Cap−Drop LED Driver Topology with Triac Dimming (120 VAC Example): This circuit has the addition of a Triac Edge Detect circuit to switch the LED string on and off. The circuit is comprised of: D5, D6, D10, CCR2, R12, R13 & M3. The circuit detects the triac waveform and turns the MOSFET M3 on. CCR2 provides a basic load to the triac to keep it functioning correctly. To set up the CCRACGEVB for the Cap-Drop LED driver dimming topology, place jumpers according to Table 5. Figure 8 depicts the schematic with the evaluation board reference designators. Table 5. JUMPERS PLACED ONTO THE EVB Jumpers in Place Reference Data J2, J13, J18, J19, J20, J21, J25, J26 Appendix F www.onsemi.com 5 CCRACGEVB Figure 8. Cap−Drop LED Driver with Triac Dimming (120 VAC example) Chopper LED Driver Topology 85 VAC to 250 VAC, Non−dimming: Chopper LED Driver Topology 85 VAC to 250 VAC, with Triac Dimming: The Chopper circuit is selected for high efficiency and a wide input voltage range. To set up the CCRACGEVB for the Chopper LED driver non-dimming topology, place jumpers according to Table 6. Figure 9 depicts the schematic with the evaluation board reference designators. This circuit is the same as Figure 9 with the addition of the Triac Dimming Detect circuit as described in the Cap-Drop description above (Figure 8). To setup the CCRACGEVB for the Chopper LED driver non-dimming topology, place jumpers according to Table 7. Figure 10 depicts the schematic with the evaluation board reference designators. Table 6. JUMPERS PLACED ONTO THE EVB Jumpers in Place Reference Data J1, J8, J10, J13, J19, J22, J25, J26 Appendix G Table 7. JUMPERS PLACED ONTO THE EVB Jumpers in Place Reference Data J1, J8, J13, J10, J19, J21, J25, J26 Appendix H The operation of the Chopper circuit can be broken into two sub-circuits; a simple buck and a straight LED driver with output capacitance. The AC is then rectified using an AC bridge (D1 – D4). A CCR (CCR3, 4, 5 or 6) controls the current through the LED string. The Buck circuit is comprised of a voltage divider R8 & R16/R10 that are used to set the voltage through TL431, that the MOSFET switch M2 turns off. When the output from the bridge is below the set voltage, M2 is ON and capacitor C7/C8 is charged. If the voltage is above the threshold voltage Vf of the LED string, then the CCR will limit the current through the LEDs. When the voltage is above the set voltage, the MOSFET is turned OFF. The LEDs then draw current from the charge on capacitor C7/C8 which is limited by the CCR. www.onsemi.com 6 CCRACGEVB Figure 9. Chopper Non−dimming LED Driver (85 VAC to 230 VAC example) Figure 10. Chopper LED Driver with Dimming (85 VAC to 230 VAC example) www.onsemi.com 7 CCRACGEVB APPENDIX A Straight LED Driver, Non−dimming (120 VAC Example) Table 8. PERFORMANCE EVALUATION Power Factor THD [%] Efficiency [%] Input Power [W] 0.96 26.7 62.7 5.5 Figure 11. Bridge Output, LED, LED Current and CCR VAK Waveforms Figure 12. Input Current and Voltage Waveforms from Power Main www.onsemi.com 8 CCRACGEVB Figure 13. Straight LED Driver, Non−dimming Circuitry Flow (120 VAC) www.onsemi.com 9 CCRACGEVB APPENDIX B Straight LED Driver, Non−dimming, with Output Capacitor (120 VAC Example) Table 9. PERFORMANCE EVALUATION Power Factor THD [%] Efficiency [%] Input Power [W] 0.63 65.9 68.2 6.8 Figure 14. Bridge Output, LED, LED Current and CCR VAK Waveforms Figure 15. Input Current and Voltage Waveforms from Power Main www.onsemi.com 10 CCRACGEVB Figure 16. Straight LED Driver, Non−dimming w/Cap Circuitry Flow (120 VAC) www.onsemi.com 11 CCRACGEVB APPENDIX C Straight LED Driver, with Triac Dimming (120 VAC Example) Table 10. PERFORMANCE EVALUATION Power Factor THD [%] Efficiency [%] Input Power [W] 0.93 36.1 59.4 4.3 Figure 17. Bridge Output, LED, LED Current and CCR VAK Waveforms (Full Brightness) Figure 18. Bridge Output, LED, LED Current and CCR VAK Waveforms (50% Dimmed) www.onsemi.com 12 CCRACGEVB Figure 19. Straight LED Driver, with Triac Dimming Circuitry Flow (120 VAC) www.onsemi.com 13 CCRACGEVB APPENDIX D Cap−Drop LED Driver Topology, Non−dimming (120 VAC Example) Table 11. PERFORMANCE EVALUATION Power Factor THD [%] Efficiency [%] Input Power [W] 0.76 41.24 54.6 3.47 Figure 20. Bridge Output, LED, LED Current and CCR VAK Waveforms Figure 21. Input Current and Voltage Waveforms from Power Main www.onsemi.com 14 CCRACGEVB Figure 22. Cap−Drop LED Driver Topology, Non−dimming Circuitry Flow (120 VAC) www.onsemi.com 15 CCRACGEVB APPENDIX E Cap−Drop LED Driver Topology, Non−dimming (230 VAC Example) Table 12. PERFORMANCE EVALUATION Power Factor THD [%] Efficiency [%] Input Power [W] 0.88 41.6 74.6 7.76 Figure 23. Bridge Output, LED, LED Current and CCR VAK Waveforms Figure 24. Input Current and Voltage Waveforms from Power Main www.onsemi.com 16 CCRACGEVB Figure 25. Cap−Drop LED Driver Topology, Non−dimming Circuitry Flow (230 VAC) www.onsemi.com 17 CCRACGEVB APPENDIX F Cap−Drop LED Driver Topology with Triac Dimming (120 VAC Example) Figure 26. Cap−Drop LED Driver Topology with Triac Dimming Circuitry Flow (120 VAC) www.onsemi.com 18 CCRACGEVB APPENDIX G Chopper LED Driver Topology 85 VAC to 250 VAC, Non−dimming Table 13. PERFORMANCE EVALUATION (85 VAC) Power Factor THD [%] Efficiency [%] Input Power [W] 0.48 83.6 82.4 3.6 Figure 27. Bridge Output, LED, LED Current and CCR VAK Waveforms (85 VAC) Figure 28. Input Current and Voltage Waveforms from Power Main (85 VAC) www.onsemi.com 19 CCRACGEVB Table 14. PERFORMANCE EVALUATION (230 VAC) Power Factor THD [%] Efficiency [%] Input Power [W] 0.2 96.78 32.4 10.3 Figure 29. Bridge Output, LED, LED Current and CCR VAK Waveforms (230 VAC) Figure 30. Input Current and Voltage Waveforms from Power Main (230 VAC) www.onsemi.com 20 CCRACGEVB Figure 31. Chopper LED Driver Topology 85 VAC to 250 VAC, Non−dimming Circuitry Flow www.onsemi.com 21 CCRACGEVB APPENDIX H Chopper LED Driver Topology 85 VAC to 250 VAC, with Triac Dimming Figure 32. Chopper LED Driver Topology 85 VAC to 250 VAC, with Triac Dimming Circuitry Flow www.onsemi.com 22 CCRACGEVB APPENDIX I Table 15. JUMPERS FUNCTION DEFINITION Jumper Function J1 Bypass Cap Drop Circuit J2 Enable C1 J3 Enable C2 J4 Enable C3 J5 Enable C4 J6 Enable C5 J7 Enable Straight Dimmable Circuit J8 Enable Chopper Circuit J9 Enable Zener Diode for Cap Drop Circuit J10 Enable Output Capacitors J11 Enable CCR3 for all Circuits J12 Enable CCR4 for all Circuits J13 Enable CCR5 for all Circuits J14 Enable CCR6 for all Circuits J15 Allows Selection of R3 for Straight Dimmable Circuit J16 Allows Selection of R4 for Straight Dimmable Circuit J17 Allows CCR6 Current to be adjusted J18 Bypass Inrush Current Limiter J19 Bypass Straight Dimmable Adjustable Resistor J20 Bypass Chopper FET J21 Enable Chopper/Cap Drop Dimmable Circuit J22 Bypass Chopper/Cap Drop Dimmable Circuit FET J23 Enable parallel LED Strings (2 Strings of 3-5 LEDs in parallel) J24 Enable Extended Straight LED String (6-10 in series) J25 Bypass LEDs D14 and D15 J26 Enable single LED String or parallel LED String J27 Bypass LEDs D19 and D20 J28 Bypass C7 ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). 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