LM3444MR16BSTRB/NOPB

Reference Design Lighting Power Products Longmont Design Center LM3444 MR16 Boost Reference Design for Non-Dimming & Dimming LED Applications Feb 13, 2012 Revision 3.0 NATIONAL SEMICONDUCTOR Page 1 of 20 Table of Contents MR16 Halogen/SSL Retro-Fit Analysis ...................................................................................................................... 3 Differences between Magnetic and Electronic Transformers .................................................................................................... 3 SSL MR16 lamps compatibility concerns with ELVT and ELV dimmers (true retro-fit) ............................................................... 3 Halogen vs SSL MR16 waveforms ............................................................................................................................................... 4 Halogen MR16 .............................................................................................................................................................. 5 LM3444 MR16 Boost Reference Design .................................................................................................................... 7 Operating Specifications ............................................................................................................................................................. 7 Schematic.................................................................................................................................................................................... 8 PCB Layout .................................................................................................................................................................................. 8 Bill of Materials ........................................................................................................................................................................... 9 Typical Performance ................................................................................................................................................................ 10 Dimming Waveforms ................................................................................................................................................................ 13 Thermal Analysis .......................................................................................................................................................15 Reference Design Transformer Compatibility ........................................................................................................16 Performance with and without Transformer ...........................................................................................................17 Revision History .........................................................................................................................................................20 LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 2 of 20 MR16 Halogen/SSL Retro-Fit Analysis Differences between Magnetic and Electronic Transformers Magnetic Transformers Magnetic transformers step down 120VAC line voltage to 12VAC. Magnetic transformers consist only of magnetic core, and copper wire, no electronics are used to step down the voltage from 120VAC to 12VAC. Due to the fact that the frequency of operation is 50Hz or 60Hz, the size of the Magnetic transformers is large and heavy. Magnetic transformers are primarily available in two types of construction; torroidal and laminated EI core. With existing Halogen MR16 systems that require dimming, Magnetic Low Voltage Dimmers are required to be used. Electronic Transformers Electronic transformers also step down 120VAC line voltage to 12VAC. Electronic transformers are much smaller and more efficient than magnetic transformers. Electronic transformers are more common than magnetic transformers in existing Halogen MR16 system. Electronic Low Voltage Transformers (ELVT) consists of a small self resonant tank power supply. Electronic Low Voltage Dimmers (ELV dimmers) are used with ELVT for dimming systems. Although electronic transformers are more complex, with many more components, that their magnetic counterparts, electronic transformers are far less expensive and smaller. The shear amount of core material and copper within a magnetic transformer adds cost, and the weight of the product makes it expensive to manufacture, and ship. SSL MR16 lamps compatibility concerns with ELVT and ELV dimmers (true retro-fit) Electronic transformers modulate (PWM) the input AC voltage with a frequency of 35 kHz to150 kHz. This waveform is step-down from 120V or 230V (typical) to 12VAC with a transformer. The higher switching frequency allows for the smaller magnetic components, and the overall smaller design. As mentioned earlier, the electronic transformer is a self driven resonant half bridge topology. The self resonance half-bridge topology requires the converter to have a minimal load at all times to function properly. Common minimum loads for ELV dimmers are from 6W – 12W depending on manufacture, and maximum power rating of the ELVT. With traditional Halogen lamps, the minimal load is of no concern, common Halogen MR16 lamps use about 50W of power per lamp. These lamps are very inefficient, and 10W of Halogen power produces very little light. With the current efficacy of the LEDs above 100 lumens per watt, 6W of SSL power is equivalent to about 40W to 50W of Halogen power. One can quickly see the compatibility issue of SSL MR16 lamps and the ELVT’s. If the output power of the ELVT reduces below the minimum requirement, the ELV dimmer will stop operating. The turning on, and off of the ELVT will cause visible flicker from the SSL MR16 lamp, and could also cause reliability issues with the lamp or ELVT. LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 3 of 20 Halogen vs SSL MR16 waveforms Halogen MR16 waveforms    Improper SSL MR16 operating waveform Channel - 1 (yellow trace) = Input line voltage Channel - 3 (purple trace) = Input line current Channel - 4 (green trace) = bulb current Issue #1 - The two scope captures above illustrate the SSL MR16 technical challenges. Figure one shows typical Halogen MR16 waveforms, and figure two is common MR16 replacement bulbs waveforms. The SSL replacement bulb looks capacitive to the ELVT; therefore large current spikes charge the energy storage device within the SSL MR16 bulb. The switching converter within the bulb then processes the input power from the energy storage element to the LED load. At this time the minimum load requirement of the ELVT is not satisfied, and the ELVT turns off. Once the energy is depleted within the MR16 converter, the ELVT will start up, and the process cycles. The turning off/on of the ELVT will manifest itself as visible flicker. Issue #2 – The maximum input current to the Halogen bulb is approximately 4.25A. The maximum input current to the SSL bulb is approximately 12A. The large magnitude spike associated with charging the SSL MR16 input capacitor can cause premature failures within the SSL bulb, or even the ELVT. LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 4 of 20 Halogen MR16 Summary: No flickering observed. There is a delay (1.12ms, 24° angle) from when the supply voltage starts ramping up from zero volts to when the electronic transformer starts to operate and the bulb turns on. This delay shows up on the LED MR16s as well although the magnitude of delay does vary from bulb to bulb. No current spikes observed out of the transformer. The bench set-up diagram below was used in the evaluation of the halogen MR16 bulb. The following scope plots show voltage and current waveforms designated by the labels indicated in the bench set-up diagram. The electronic transformer used was the Lightech LET-75. Bench Circuit IIN LINE 120VAC Power Supply LINE VIN NEUTRAL +12V 12V, 50W Halogen MR16 Bulb IBULB Transformer (Electronic) NEUTRAL SGND VBULB VIN (Yellow), IIN (Magenta), IBULB (Green) LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 5 of 20 VIN (Yellow), IIN (Magenta), IBULB (Green) VBULB (Blue), IBULB (Green) LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 6 of 20 LM3444 Boost MR16 Reference Design This reference design was based on the released LM3444 IC from National Semiconductor. This design was developed to minimize the current spikes coming out of an electronic transformer to less than 5A, which is a typical transformer rating, when driving an LED MR16 circuit. The off the shelf LED MR16 solutions exhibit spikes that significantly exceed a transformer’s maximum rated output current which will degrade the reliability of the transformer and reduce its operating lifetime. This design generates a continuous LED current when a 220uF 35V electrolytic capacitor is placed across the output. The circuit operates in a constant output power mode. The output power is fixed at about 6W. Operating Specifications NOTE: The following specifications are typical values based on the LED driver being powered directly by a 12VAC supply (i.e. no electronic or magnetic step-down transformer). Input Voltage, VIN: ............................................................................................................................................. 12 VAC Output Voltage, VOUT: ................................................................................................... 23.5V (Single string of 7 LEDs) Input Current, IIN .................................................................................................................................................. 710mA LED Output Current, ILED ..................................................................................................................................... 280mA Input Power, PIN .................................................................................................................................................. ~ 8.0W Output Power, POUT ............................................................................................................................................. ~ 6.6W Efficiency ............................................................................................................................................................. ~ 83 % Power Factor ........................................................................................................................................................ ~ 0.95 Input Voltage, VIN: ............................................................................................................................................. 12 VAC Output Voltage, VOUT: ................................................................................................... 26.6V (Single string of 8 LEDs) Input Current, IIN .................................................................................................................................................. 680mA LED Output Current, ILED ..................................................................................................................................... 240mA Input Power, PIN .................................................................................................................................................. ~ 7.7W Output Power, POUT ............................................................................................................................................. ~ 6.4W Efficiency ............................................................................................................................................................. ~ 83 % Power Factor ........................................................................................................................................................ ~ 0.95 Input Voltage, VIN: ............................................................................................................................................. 12 VAC Output Voltage, VOUT: ................................................................................................... 28.2V (Single string of 9 LEDs) Input Current, IIN .................................................................................................................................................. 670mA LED Output Current, ILED ..................................................................................................................................... 220mA Input Power, PIN .................................................................................................................................................. ~ 7.5W Output Power, POUT ............................................................................................................................................. ~ 6.2W Efficiency ............................................................................................................................................................. ~ 83 % Power Factor ........................................................................................................................................................ ~ 0.95 SMPS Topology .................................................................................................................................................... Boost LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 7 of 20 PCB Schematic PCB Layout LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 8 of 20 Bill of Materials Designator Description MFG Part Number C1 CAP, CERM, 1.0uF, 25V, +/-10%, X5R, 0805 MuRata GRM216R61E105KA12D C2 CAP, ELECT, 220uF, 35V, +/-20%, Radial 8x11.5mm Panasonic ECA-1VHG221 C3 CAP, CERM, 22uF, 25V, +/-10%, X5R, 1210 MuRata GRM32ER61E226KE15L C4 CAP, CERM, 330pF, 100V, +/-5%, X7R, 0603 AVX 06031C331JAT2A C5 CAP, CERM, 4.7uF, 50V, +/-10%, X7R, 1210 MuRata GRM32ER71H475KA882 C6 CAP, CERM, 4.7uF, 25V, +/-10%, X5R, 0805 MuRata GRM21BR61E475KA12L D1-D4 Diode, Schottky, 30V, 3A, SMA Diodes Inc. B330A-13-F D5 Diode, Schottky, 60V, 1A, SMA Diodes Inc. B160-13-F D6 TVS BI-DIR 24V 400W SMA (Optional) Diodes Inc SMAJ24CA-13-F D7 Diode, Zener, 11V, 500mW, SOD-123 Central Semiconductor CMHZ4698 D8 Diode, Zener, 33V, 500mW, SOD-123 Central Semiconductor CMHZ4714 D9 Diode, Schottky, 75V, 150mA, SOD-323 Fairchild 1N4148WS L1 Ind, Shielded Drum Core, Ferrite, 33uH, 1.1A, 0.31 ohm, SMD Coilcraft MSS6132-333MLB Q1 Transistor, NPN, 80V, 500mA, SOT-23 Central Semiconductor CMPTA06 Q2 MOSFET, N-CH, 60V, 1.2A, SOT-23 Diodes Inc. ZXMN6A07FTA R1 RES, 0.1 ohm, 5%, 0.125W, 0805 Panasonic ERJ-6RSJR10V R2, R4 RES, 1.00k ohm, 1%, 0.1W, 0603 Vishay-Dale R3 RES, 12.4k ohm, 1%, 0.1W, 0603 Vishay-Dale CRCW06031K00FKEA ERJ-6GEYJ4R7V CRCW060312k4FKEA R5 RES, 1.00 ohm, 1%, 0.5W, 1206 Stackpole Electronics Inc CSR1206FK1R00 R6 RES, 4.7 ohm, 5%, 0.125W, 0805 Yageo RC0805JR-074R7L U1 AC-DC Off Line LED Driver National Semiconductor LM3444MM LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 9 of 20 Typical Performance (Eight series LEDs) Bench Circuit I1 LINE 120VAC Power Supply NEUTRAL I3 I2 Vp Vs Transformer V1 (Electronic) Vp Vs VIN V2 LM3444 MR16 LED Driver VIN LED Board LED+ V3 LED- The following scope plots show voltage and current waveforms designated by the labels indicated in the following bench set-up diagram. The electronic transformer used was the Lightech LET-75. CH2 V1 Voltage, CH4 I3 Current LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 10 of 20 CH2 V1 Voltage, CH4 I2 Current 4.4A peak CH2 V1 Voltage, CH4 I2 Current LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 11 of 20 CH2 V2 Voltage, CH4 I2 Current LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 12 of 20 LM3444 MR16 Boost evaluation board Dimming Waveforms Bench Circuit I1 Vp LINE 120VAC Power Supply V1 Triac Dimmer V2 NEUTRAL I4 I3 I2 Vs Transformer ( Electronic ) Vp Vs VIN V3 VIN LED Board LED+ LM3444 MR16 LED Driver V4 LED- This LM3444 MR16 Boost evaluation board is designed to operate (flicker-free) with common Electronic Low Voltage dimmers, and Electronic Transformers. Dimmer Used – Lutron SELV-300P-GR Electronic Transformer – Lightech LET75 20:1 dimming ratio LM3444 MR16 Boost - Eight series connected LEDs at 200mA (90° Conduction Angle) CH2 V2 Voltage, CH4 I4 Current LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 13 of 20 LM3444 MR16 Boost - Eight series connected LEDs at 100mA (45° Conduction Angle) CH2 V2 Voltage, CH4 I4 Current LM3444 MR16 Boost - Eight series connected LEDs at 10mA (minimum Conduction Angle) CH2 V2 Voltage, CH4 I4 Current LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 14 of 20 Thermal Analysis LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 15 of 20 Reference Design Transformer Compatibility The following transformers were tested with the National LED driver designs described in this document. A compatibility matrix is shown below which describes which driver/transformer combinations are suitable (i.e. no flicker, stable operation). Electronic Transformers (120VAC to 12VAC): Lightech, Model: LET-60, 60W Lightech, Model: LET-75, 75W Lightech, Model: LET-60 LW, 60W Hatch, Model: RS12-80M, 80W Hatch, Model: RS12-60, 60W Pony, Model: PET-120-12-60, 60W Eurofase, Model: 0084 CLASS 2, 60W Magnetic Transformers (120VAC to 12VAC): Hatch, Model: LS1275EN, 75VA LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 16 of 20 Performance with 7 LEDs Performance without transformer The table below compares the performance of each reference design when powered directly by a 12VAC source LM3441 BOOST 7 LEDs 11.91 0.708 7.97 23.55 0.281 6.62 83.0% 0.948 Units VAC A W VDC A W - Specs VIN IIN PIN (1) VOUT (1) ILED (2) POUT Efficiency Power Factor LM3444 BOOST 7 LEDs 120 0.07 8.18 23.5 0.270 6.23 77.6% 0.970 Units VAC A W VDC A W - Specs VIN IIN PIN VOUT ILED POUT Efficiency Power Factor LM3444 BOOST 7 LEDs 2 LEDs 120@ 1A 0.072 8.13 23.5 0.270 6.23 78.0% 0.934 Units VAC A W VDC A W - Specs VIN IIN PIN (1) VOUT (1) ILED (2) POUT Efficiency Power Factor Performance with transformer LET-75 HATCH RS12-80M LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 17 of 20 Performance with 8 LEDs Performance without transformer The table below compares the performance of each reference design when powered directly by a 12VAC source LM3441 BOOST 8 LEDs 11.91 0.682 7.66 26.64 0.238 6.34 82.8% 0.946 Units VAC A W VDC A W - Specs VIN IIN PIN VOUT ILED POUT Efficiency Power Factor LM3444 BOOST 8 LEDs 120 0.067 7.86 26.5 0.230 6.10 77.5% 0.970 Units VAC A W VDC A W - Specs VIN IIN PIN VOUT ILED POUT Efficiency Power Factor LM3444 BOOST 8 LEDs 2 LEDs 120@ 1A 0.069 7.82 26.5 0.230 6.10 77.9% 0.930 Units VAC A W VDC A W - Specs VIN IIN PIN (1) VOUT (1) ILED (2) POUT Efficiency Power Factor Performance with transformer LET-75 HATCH RS12-80M LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 18 of 20 Performance with 9 LEDs Performance without transformer The table below compares the performance of each reference design when powered directly by a 12VAC source LM3441 BOOST 9 LEDs 11.92 0.668 7.51 28.25 0.220 6.22 82.8% 0.946 Units VAC A W VDC A W - Specs VIN IIN PIN VOUT ILED POUT Efficiency Power Factor LM3444 BOOST 9 LEDs 120 0.066 7.74 28.0 0.215 6.02 77.8% 0.970 Units VAC A W VDC A W - Specs VIN IIN PIN VOUT ILED POUT Efficiency Power Factor LM3444 BOOST 9 LEDs 2 LEDs 120@ 1A 0.068 7.64 28.0 0.212 5.94 77.7% 0.930 Units VAC A W VDC A W - Specs VIN IIN PIN (1) VOUT (1) ILED (2) POUT Efficiency Power Factor Performance with transformer LET-75 HATCH RS12-80M LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR Page 19 of 20 Revision History Date 10/14/2011 02/13/2012 Author David Zhang David Zhang Revision 2 3 LM3444-MR16-Boost Reference Design Description Added D9 Change D9 P/N NATIONAL SEMICONDUCTOR Page 20 of 20 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications, enhancements, improvements, and other changes to its products and services at any time and to discontinue any product or service without notice. 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