LM3444MA/NOPB [TI]

交流/直流离线式 LED 驱动器 | D | 8 | -40 to 125;
LM3444MA/NOPB
型号: LM3444MA/NOPB
厂家: TEXAS INSTRUMENTS    TEXAS INSTRUMENTS
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交流/直流离线式 LED 驱动器 | D | 8 | -40 to 125

驱动 驱动器
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LM3444  
LM3444 AC-DC Offline LED Driver  
Literature Number: SNVS682B  
November 17, 2011  
LM3444  
AC-DC Offline LED Driver  
General Description  
Features  
The LM3444 is an adaptive constant off-time AC/DC buck  
(step-down) constant current controller that provides a con-  
stant current for illuminating high power LEDs. The high fre-  
quency capable architecture allows the use of small external  
passive components. A passive PFC circuit ensures good  
power factor by drawing current directly from the line for most  
of the cycle, and provides a constant positive voltage to the  
buck regulator. Additional features include thermal shutdown,  
current limit and VCC under-voltage lockout. The LM3444 is  
available in a low profile MSOP-10 package or an 8 lead SOIC  
package.  
Application voltage range 80VAC – 277VAC  
Capable of controlling LED currents greater than 1A  
Adjustable switching frequency  
Low quiescent current  
Adaptive programmable off-time allows for constant ripple  
current  
Thermal shutdown  
No 120Hz flicker  
Low profile 10 pin MSOP package or 8 lead SOIC package  
Patent pending drive architecture  
Applications  
Solid State Lighting  
Industrial and Commercial Lighting  
Residential Lighting  
Typical LM3444 LED Driver Application Circuit  
30127505  
30127501  
© 2011 Texas Instruments Incorporated  
301275  
www.ti.com  
Connection Diagrams  
Top View  
Top View  
30127503  
8-Pin SOIC  
NS Package Number M08A  
30127573  
10-Pin MSOP  
NS Package Number MUB10A  
Ordering Information  
NSC Package  
Drawing  
Order Number  
Spec.  
Package Type  
Top Mark  
Supplied As  
LM3444MM  
LM3444MMX  
LM3444MA  
LM3444MAX  
NOPB  
NOPB  
NOPB  
NOPB  
MSOP-10  
MSOP-10  
SOIC-8  
MUB10A  
MUB10A  
M08A  
SZTB  
SZTB  
1000 Units, Tape and Reel  
3500 Units, Tape and Reel  
LM3444MA 95 Units, Rail  
SOIC-8  
M08A  
LM3444MA 2500 Units, Tape and Reel  
Pin Descriptions  
MSOP  
SOIC  
Name  
NC  
Description  
1
2
3
4
1
No internal connection. Leave this pin open.  
No internal connection. Leave this pin open.  
No internal connection. Leave this pin open.  
NC  
NC  
8
2
COFF  
OFF time setting pin. A user set current and capacitor connected from the output to this pin sets  
the constant OFF time of the switching controller.  
5
FILTER  
Filter input. A low pass filter tied to this pin can filter a PWM dimming signal to supply a DC  
voltage to control the LED current. Can also be used as an analog dimming input. If not used for  
dimming connect a 0.1µF capacitor from this pin to ground.  
6
7
3
4
GND  
ISNS  
Circuit ground connection.  
LED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND  
to set the maximum LED current.  
8
5
GATE  
Power MOSFET driver pin. This output provides the gate drive for the power switching MOSFET  
of the buck controller.  
9
6
7
VCC  
NC  
Input voltage pin. This pin provides the power for the internal control circuitry and gate driver.  
No internal connection. Leave this pin open.  
10  
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2
ESD Susceptibility  
HBM (Note 3)  
Junction Temperature (TJ-MAX  
Absolute Maximum Ratings (Note 1)  
If Military/Aerospace specified devices are required,  
please contact the Texas Instruments Sales Office/  
Distributors for availability and specifications.  
2 kV  
150°C  
)
Storage Temperature Range  
-65°C to +150°C  
Maximum Lead Temp.  
Range (Soldering)  
VCC and GATE to GND  
ISNS to GND  
FILTER and COFF to GND  
COFF Input Current  
Continuous Power Dissipation  
(Note 2)  
-0.3V to +14V  
-0.3V to +2.5V  
-0.3V to +7.0V  
60mA  
260°C  
Operating Conditions  
VCC  
8.0V to 13V  
Internally Limited  
Junction Temperature  
−40°C to +125°C  
Electrical Characteristics Limits in standard type face are for TJ = 25°C and those with boldface type apply  
over the full Operating Temperature Range ( TJ = −40°C to +125°C). Minimum and Maximum limits are guaranteed through test,  
design, or statistical correlation. Typical values represent the most likely parametric norm at TJ = +25ºC, and are provided for  
reference purposes only. Unless otherwise stated the following conditions apply: VCC = 12V.  
Symbol  
VCC SUPPLY  
IVCC  
Parameter  
Conditions  
Min Typ  
Max Units  
Operating supply current  
Rising threshold  
Falling threshold  
Hysterisis  
1.58  
7.4  
2.25  
7.7  
mA  
V
VCC-UVLO  
6.0  
6.4  
1
COFF  
VCOFF  
Time out threshold  
Off timer sinking impedance  
Restart timer  
1.225 1.276 1.327  
V
RCOFF  
33  
60  
µs  
tCOFF  
180  
CURRENT LIMIT  
VISNS  
ISNS limit threshold  
1.174 1.269 1.364  
V
tISNS  
Leading edge blanking time  
Current limit reset delay  
ISNS limit to GATE delay  
125  
180  
33  
ns  
µs  
ns  
ISNS = 0 to 1.75V step  
CURRENT SENSE COMPARATOR  
VFILTER  
RFILTER  
VOS  
FILTER open circuit voltage  
720  
-4.0  
750  
1.12  
0.1  
780  
4.0  
mV  
FILTER impedance  
MΩ  
mV  
Current sense comparator offset voltage  
GATE DRIVE OUTPUT  
VDRVH  
VDRVL  
IDRV  
GATE high saturation  
IGATE = 50 mA  
IGATE = 100 mA  
GATE = VCC/2  
GATE = VCC/2  
Cload = 1 nF  
0.24  
0.22  
-0.77  
0.88  
15  
0.50  
0.50  
V
A
GATE low saturation  
Peak souce current  
Peak sink current  
Rise time  
tDV  
ns  
Fall time  
Cload = 1 nF  
15  
THERMAL SHUTDOWN  
TSD Thermal shutdown temperature  
Thermal shutdown hysteresis  
THERMAL SPECIFICATION  
(Note 4)  
165  
20  
°C  
RθJA  
RθJC  
MSOP-10 junction to ambient  
MSOP-10 junction to case  
124  
76  
°C/W  
Note 1: Absolute maximum ratings are limits beyond which damage to the device may occur. Operating Ratings are conditions for which the device is intended  
to be functional, but device parameter specifications may not be guaranteed. For guaranteed specifications and test conditions, see the Electrical Characteristics.  
All voltages are with respect to the potential at the GND pin, unless otherwise specified.  
Note 2: Internal thermal shutdown circuitry protects the device from permanent damage. Thermal shutdown engages at TJ = 165°C (typ.) and disengages at TJ  
= 145°C (typ).  
Note 3: Human Body Model, applicable std. JESD22-A114-C.  
3
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Note 4: Junction-to-ambient thermal resistance is highly application and board-layout dependent. In applications where high maximum power dissipation exists,  
special care must be paid to thermal dissipation issues in board design. In applications where high power dissipation and/or poor package thermal resistance is  
present, the maximum ambient temperature may have to be derated. Maximum ambient temperature (TA-MAX) is dependent on the maximum operating junction  
temperature (TJ-MAX-OP = 125°C), the maximum power dissipation of the device in the application (PD-MAX), and the junction-to ambient thermal resistance of the  
part/package in the application (RθJA), as given by the following equation: TA-MAX = TJ-MAX-OP – (RθJA × PD-MAX).  
Typical Performance Characteristics  
fSW vs Input Line Voltage  
Efficiency vs Input Line Voltage  
30127504  
30127505  
VCC UVLO vs Temperature  
Min On-Time (tON) vs Temperature  
30127507  
30127508  
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Off Threshold (C11) vs Temperature  
1.29  
Normalized Variation in fSW over VBUCK Voltage  
1.28  
1.27  
1.26  
1.25  
OFF Threshold at C11  
-50 -30 -10 10 30 50 70 90 110130150  
TEMPERATURE (°C)  
30127510  
30127574  
Leading Edge Blanking Variation Over Temperature  
30127572  
5
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Simplified Internal Block Diagram  
30127511  
FIGURE 1. Simplified Block Diagram  
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Application Information  
Theory of Operation  
Refer to Figure 2 below which shows the LM3444 along with  
FUNCTIONAL DESCRIPTION  
basic external circuitry.  
The LM3444 contains all the necessary circuitry to build a line-  
powered (mains powered) constant current LED driver.  
30127501  
FIGURE 2. LM3444 Schematic  
7
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VALLEY-FILL CIRCUIT  
charged. However, the network of diodes and capacitors  
shown between D3 and C10 make up a "valley-fill" circuit. The  
valley-fill circuit can be configured with two or three stages.  
The most common configuration is two stages. Figure 3 illus-  
trates a two and three stage valley-fill circuit.  
VBUCK supplies the power which drives the LED string. Diode  
D3 allows VBUCK to remain high while V+ cycles on and off.  
VBUCK has a relatively small hold capacitor C10 which reduces  
the voltage ripple when the valley fill capacitors are being  
30127518  
FIGURE 3. Two and Three Stage Valley Fill Circuit  
The valley-fill circuit allows the buck regulator to draw power  
throughout a larger portion of the AC line. This allows the ca-  
pacitance needed at VBUCK to be lower than if there were no  
valley-fill circuit, and adds passive power factor correction  
(PFC) to the application.  
pacitors are placed in parallel to each other (Figure 5), and  
VBUCK equals the capacitor voltage.  
VALLEY-FILL OPERATION  
When the “input line is high”, power is derived directly through  
D3. The term “input line is high” can be explained as follows.  
The valley-fill circuit charges capacitors C7 and C9 in series  
(Figure 4) when the input line is high.  
30127521  
FIGURE 5. Two stage Valley-Fill Circuit when AC Line is  
Low  
A three stage valley-fill circuit performs exactly the same as  
two-stage valley-fill circuit except now three capacitors are  
now charged in series, and when the line voltage decreases  
to:  
30127519  
FIGURE 4. Two stage Valley-Fill Circuit when AC Line is  
High  
The peak voltage of a two stage valley-fill capacitor is:  
Diode D3 is reversed biased and three capacitors are in par-  
allel to each other.  
The valley-fill circuit can be optimized for power factor, volt-  
age hold up and overall application size and cost. The  
LM3444 will operate with a single stage or a three stage val-  
ley-fill circuit as well. Resistor R8 functions as a current  
limiting resistor during start-up, and during the transition from  
series to parallel connection. Resistors R6 and R7 are 1 MΩ  
bleeder resistors, and may or may not be necessary for each  
application.  
As the AC line decreases from its peak value every cycle,  
there will be a point where the voltage magnitude of the AC  
line is equal to the voltage that each capacitor is charged. At  
this point diode D3 becomes reversed biased, and the ca-  
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BUCK CONVERTER  
voltage, transistor Q2 is turned off and diode D10 conducts  
the current through the inductor and LEDs. Capacitor C12  
eliminates most of the ripple current seen in the inductor. Re-  
sistor R4, capacitor C11, and transistor Q3 provide a linear  
current ramp that sets the constant off-time for a given output  
voltage.  
The LM3444 is a buck controller that uses a proprietary con-  
stant off-time method to maintain constant current through a  
string of LEDs. While transistor Q2 is on, current ramps up  
through the inductor and LED string. A resistor R3 senses this  
current and this voltage is compared to the reference voltage  
at FILTER. When this sensed voltage is equal to the reference  
30127523  
FIGURE 6. LM3444 Buck Regulation Circuit  
OVERVIEW OF CONSTANT OFF-TIME CONTROL  
the ISNS pin. This sensed voltage across R3 is compared  
against the voltage of FILTER, at which point Q2 is turned off  
by the controller.  
A buck converter’s conversion ratio is defined as:  
Constant off-time control architecture operates by simply  
defining the off-time and allowing the on-time, and therefore  
the switching frequency, to vary as either VIN or VO changes.  
The output voltage is equal to the LED string voltage (VLED),  
and should not change significantly for a given application.  
The input voltage or VBUCK in this analysis will vary as the  
input line varies. The length of the on-time is determined by  
the sensed inductor current through a resistor to a voltage  
reference at a comparator. During the on-time, denoted by  
tON, MOSFET switch Q2 is on causing the inductor current to  
30127525  
increase. During the on-time, current flows from VBUCK  
,
through the LEDs, through L2, Q2, and finally through R3 to  
ground. At some point in time, the inductor current reaches a  
maximum (IL2-PK) determined by the voltage sensed at R3 and  
FIGURE 7. Inductor Current Waveform in CCM  
9
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During the off-period denoted by tOFF, the current through L2  
continues to flow through the LEDs via D10.  
THERMAL SHUTDOWN  
With efficiency of the buck converter in mind:  
Substitute equations and rearrange:  
Thermal shutdown limits total power dissipation by turning off  
the output switch when the IC junction temperature exceeds  
165°C. After thermal shutdown occurs, the output switch  
doesn’t turn on until the junction temperature drops to ap-  
proximately 145°C.  
Design Guide  
DETERMINING DUTY-CYCLE (D)  
Duty cycle (D) approximately equals:  
Off-time, and switching frequency can now be calculated us-  
ing the equations above.  
With efficiency considered:  
SETTING THE SWITCHING FREQUENCY  
Selecting the switching frequency for nominal operating con-  
ditions is based on tradeoffs between efficiency (better at low  
frequency) and solution size/cost (smaller at high frequency).  
The input voltage to the buck converter (VBUCK) changes with  
both line variations and over the course of each half-cycle of  
the input line voltage. The voltage across the LED string will,  
however, remain constant, and therefore the off-time remains  
constant.  
For simplicity, choose efficiency between 75% and 85%.  
CALCULATING OFF-TIME  
The “Off-Time” of the LM3444 is set by the user and remains  
fairly constant as long as the voltage of the LED stack remains  
constant. Calculating the off-time is the first step in determin-  
ing the switching frequency of the converter, which is integral  
in determining some external component values.  
The on-time, and therefore the switching frequency, will vary  
as the VBUCK voltage changes with line voltage. A good design  
practice is to choose a desired nominal switching frequency  
knowing that the switching frequency will decrease as the line  
voltage drops and increase as the line voltage increases  
(Figure 8).  
PNP transistor Q3, resistor R4, and the LED string voltage  
define a charging current into capacitor C11. A constant cur-  
rent into a capacitor creates a linear charging characteristic.  
Resistor R4, capacitor C11 and the current through resistor  
R4 (iCOLL), which is approximately equal to VLED/R4, are all  
fixed. Therefore, dv is fixed and linear, and dt (tOFF) can now  
be calculated.  
Common equations for determining duty cycle and switching  
frequency in any buck converter:  
30127510  
FIGURE 8. Graphical Illustration of Switching Frequency  
vs VBUCK  
The off-time of the LM3444 can be programmed for switching  
frequencies ranging from 30 kHz to over 1 MHz. A trade-off  
between efficiency and solution size must be considered  
when designing the LM3444 application.  
The maximum switching frequency attainable is limited only  
by the minimum on-time requirement (200 ns).  
Therefore:  
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Worst case scenario for minimum on time is when VBUCK is at  
its maximum voltage (AC high line) and the LED string voltage  
(VLED) is at its minimum value.  
VL(ON-TIME) = VBUCK - VLED  
During the off-time, the voltage seen by the inductor is ap-  
proximately:  
VL(OFF-TIME) = VLED  
The value of VL(OFF-TIME) will be relatively constant, because  
the LED stack voltage will remain constant. If we rewrite the  
equation for an inductor inserting what we know about the  
circuit during the off-time, we get:  
The maximum voltage seen by the Buck Converter is:  
INDUCTOR SELECTION  
The controlled off-time architecture of the LM3444 regulates  
the average current through the inductor (L2), and therefore  
the LED string current. The input voltage to the buck converter  
(VBUCK) changes with line variations and over the course of  
each half-cycle of the input line voltage. The voltage across  
the LED string is relatively constant, and therefore the current  
through R4 is constant. This current sets the off-time of the  
converter and therefore the output volt-second product  
(VLED x off-time) remains constant. A constant volt-second  
product makes it possible to keep the ripple through the in-  
ductor constant as the voltage at VBUCK varies.  
Re-arranging this gives:  
From this we can see that the ripple current (Δi) is proportional  
to off-time (tOFF) multiplied by a voltage which is dominated  
by VLED divided by a constant (L2).  
These equations can be rearranged to calculate the desired  
value for inductor L2.  
Where:  
Finally:  
30127540  
Refer to “Design Example” section of the datasheet to better  
understand the design process.  
FIGURE 9. LM3444 External Components of the Buck  
Converter  
SETTING THE LED CURRENT  
The equation for an ideal inductor is:  
The LM3444 constant off-time control loop regulates the peak  
inductor current (IL2). The average inductor current equals the  
average LED current (IAVE). Therefore the average LED cur-  
rent is regulated by regulating the peak inductor current.  
Given a fixed inductor value, L, this equation states that the  
change in the inductor current over time is proportional to the  
voltage applied across the inductor.  
During the on-time, the voltage applied across the inductor is,  
VL(ON-TIME) = VBUCK - (VLED + VDS(Q2) + IL2 x R3)  
Since the voltage across the MOSFET switch (Q2) is rela-  
tively small, as is the voltage across sense resistor R3, we  
can simplify this to approximately,  
11  
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The valley fill capacitors should be sized to supply energy to  
the buck converter (VBUCK) when the input line is less than its  
peak divided by the number of stages used in the valley fill  
(tX). The capacitance value should be calculated for the max-  
imum LED current.  
30127525  
FIGURE 10. Inductor Current Waveform in CCM  
Knowing the desired average LED current, IAVE and the nom-  
inal inductor current ripple, ΔiL, the peak current for an appli-  
cation running in continuous conduction mode (CCM) is  
defined as follows:  
30127552  
FIGURE 11. Two Stage Valley-Ffill VBUCK Voltage  
From the above illustration and the equation for current in a  
capacitor, i = C x dV/dt, the amount of capacitance needed at  
VBUCK will be calculated as follows:  
Or the LED current would then be,  
At 60Hz, and a valley-fill circuit of two stages, the hold up time  
(tX) required at VBUCK is calculated as follows. The total angle  
of an AC half cycle is 180° and the total time of a half AC line  
cycle is 8.33 ms. When the angle of the AC waveform is at  
30° and 150°, the voltage of the AC line is exactly ½ of its  
peak. With a two stage valley-fill circuit, this is the point where  
the LED string switches from power being derived from AC  
line to power being derived from the hold up capacitors (C7  
and C9). 60° out of 180° of the cycle or 1/3 of the cycle the  
power is derived from the hold up capacitors (1/3 x 8.33 ms  
= 2.78 ms). This is equal to the hold up time (dt) from the  
above equation, and dv is the amount of voltage the circuit is  
allowed to droop. From the next section (“Determining Maxi-  
mum Number of Series Connected LEDs Allowed”) we know  
the minimum VBUCK voltage will be about 45V for a 90VAC to  
135VAC line. At 90VAC low line operating condition input, ½ of  
the peak voltage is 64V. Therefore with some margin the volt-  
age at VBUCK can not droop more than about 15V (dv). (i) is  
equal to (POUT/VBUCK), where POUT is equal to (VLED x ILED).  
Total capacitance (C7 in parallel with C9) can now be calcu-  
lated. See “ Design Example" section for further calculations  
of the valley-fill capacitors.  
This is important to calculate because this peak current mul-  
tiplied by the sense resistor R3 will determine when the  
internal comparator is tripped. The internal comparator turns  
the control MOSFET off once the peak sensed voltage reach-  
es 750 mV.  
Current Limit: The trip voltage on the PWM comparator is  
750 mV. However, if there is a short circuit or an excessive  
load on the output, higher than normal switch currents will  
cause a voltage above 1.27V on the ISNS pin which will trip  
the I-LIM comparator. The I-LIM comparator will reset the RS  
latch, turning off Q2. It will also inhibit the Start Pulse Gener-  
ator and the COFF comparator by holding the COFF pin low.  
A delay circuit will prevent the start of another cycle for 180  
µs.  
Determining Maximum Number of Series Connected  
LEDs Allowed:  
The LM3444 is an off-line buck topology LED driver. A buck  
converter topology requires that the input voltage (VBUCK) of  
the output circuit must be greater than the voltage of the LED  
stack (VLED) for proper regulation. One must determine what  
the minimum voltage observed by the buck converter will be  
before the maximum number of LEDs allowed can be deter-  
mined. Two variables will have to be determined in order to  
accomplish this.  
VALLEY FILL CAPACITORS  
Determining voltage rating and capacitance value of the val-  
ley-fill capacitors:  
The maximum voltage seen by the valley-fill capacitors is:  
1. AC line operating voltage. This is usually 90VAC to  
135VAC for North America. Although the LM3444 can  
operate at much lower and higher input voltages a range  
is needed to illustrate the design process.  
This is, of course, if the capacitors chosen have identical ca-  
pacitance values and split the line voltage equally. Often a  
20% difference in capacitance could be observed between  
like capacitors. Therefore a voltage rating margin of 25% to  
50% should be considered.  
2. How many stages are implemented in the valley-fill circuit  
(1, 2 or 3).  
In this example the most common valley-fill circuit will be used  
(two stages).  
Determining the capacitance value of the valley-fill ca-  
pacitors:  
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12  
 
that all of the ripple will be seen by the capacitor, and not the  
LEDs. One must ensure that the capacitor you choose can  
handle the RMS current of the inductor. Refer to  
manufacture’s datasheets to ensure compliance. Usually an  
X5R or X7R capacitor between 1 µF and 10 µF of the proper  
voltage rating will be sufficient.  
SWITCHING MOSFET  
The main switching MOSFET should be chosen with efficien-  
cy and robustness in mind. The maximum voltage across the  
switching MOSFET will equal:  
30127554  
The average current rating should be greater than:  
FIGURE 12. AC Line  
IDS-MAX = ILED(-AVE)(DMAX  
)
Figure 12 shows the AC waveform. One can easily see that  
the peak voltage (VPEAK) will always be:  
RE-CIRCULATING DIODE  
The LM3444 Buck converter requires a re-circulating diode  
D10 (see the Typical Application circuit Figure 2) to carry the  
inductor current during the MOSFET Q2 off-time. The most  
efficient choice for D10 is a diode with a low forward drop and  
near-zero reverse recovery time that can withstand a reverse  
voltage of the maximum voltage seen at VBUCK. For a common  
110VAC ± 20% line, the reverse voltage could be as high as  
190V.  
The voltage at VBUCK with a valley fill stage of two will look  
similar to the waveforms of Figure 11.  
The purpose of the valley fill circuit is to allow the buck con-  
verter to pull power directly off of the AC line when the line  
voltage is greater than its peak voltage divided by two (two  
stage valley fill circuit). During this time, the capacitors within  
the valley fill circuit (C7 and C8) are charged up to the peak  
of the AC line voltage. Once the line drops below its peak  
divided by two, the two capacitors are placed in parallel and  
deliver power to the buck converter. One can now see that if  
the peak of the AC line voltage is lowered due to variations in  
the line voltage the DC offset (VDC) will lower. VDC is the low-  
est value that voltage VBUCK will encounter.  
The current rating must be at least:  
ID = 1 - (DMIN) x ILED(AVE)  
Or:  
Design Example  
Example:  
The following design example illustrates the process of cal-  
culating external component values.  
Line voltage = 90VAC to 135VAC  
Valley-Fill = two stage  
Known:  
1. Input voltage range (90VAC – 135VAC  
2. Number of LEDs in series = 7  
)
3. Forward voltage drop of a single LED = 3.6V  
4. LED stack voltage = (7 x 3.6V) = 25.2V  
Choose:  
1. Nominal switching frequency, fSW-TARGET = 250 kHz  
2. ILED(AVE) = 400 mA  
Depending on what type and value of capacitors are used,  
some derating should be used for voltage droop when the  
capacitors are delivering power to the buck converter. With  
this derating, the lowest voltage the buck converter will see is  
about 42.5V in this example.  
3.  
Δi (usually 15% - 30% of ILED(AVE)) = (0.30 x 400 mA) =  
120 mA  
To determine how many LEDs can be driven, take the mini-  
mum voltage the buck converter will see (42.5V) and divide it  
by the worst case forward voltage drop of a single LED.  
4. Valley fill stages (1,2, or 3) = 2  
5. Assumed minimum efficiency = 80%  
Calculate:  
Example: 42.5V/3.7V = 11.5 LEDs (11 LEDs with margin)  
1. Calculate minimum voltage VBUCK equals:  
OUTPUT CAPACITOR  
A capacitor placed in parallel with the LED or array of LEDs  
can be used to reduce the LED current ripple while keeping  
the same average current through both the inductor and the  
LED array. With a buck topology the output inductance (L2)  
can now be lowered, making the magnetics smaller and less  
expensive. With a well designed converter, you can assume  
2. Calculate maximum voltage VBUCK equals:  
13  
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8. Calculate C11:  
9.  
3. Calculate tOFF at VBUCK nominal line voltage:  
10. Use standard value of 120 pF  
11. Calculate ripple current: 400 mA X 0.30 = 120 mA  
12. Calculate inductor value at tOFF = 3 µs:  
4. Calculate tON(MIN) at high line to ensure that  
tON(MIN) > 200 ns:  
13. Choose C10: 1.0 µF 200V  
14. Calculate valley-fill capacitor values: VAC low line =  
90VAC, VBUCK minimum equals 60V. Set droop for 20V  
maximum at full load and low line.  
5. Calculate C11 and R4:  
6. Choose current through R4: (between 50 µA and 100 µA)  
70 µA  
i) equals POUT/VBUCK (270 mA), dV equals 20V, dt equals  
2.77 ms, and then CTOTAL equals 37 µF. Therefore C7 =  
C9 = 22 µF  
7. Use a standard value of 365 kΩ  
www.ti.com  
14  
LM3444 Design Example 1  
Input = 90VAC to 135VAC, VLED = 7 x HB LED String Application @ 400 mA  
30127569  
15  
www.ti.com  
Bill of Materials  
Qty  
1
Ref Des  
U1  
Description  
Mfr  
Mfr PN  
LM3444MM  
HD04-T  
IC, CTRLR, DRVR-LED, MSOP10  
Bridge Rectifiier, SMT, 400V, 800 mA  
NSC  
1
BR1  
L1  
DiodesInc  
Panasonic  
1
Common mode filter DIP4NS, 900 mA, 700  
µH  
ELF-11090E  
1
2
1
3
L2  
L3, L4  
Inductor, SHLD, SMT, 1A, 470 µH  
Diff mode inductor, 500 mA 1 mH  
Coilcraft  
Coilcraft  
MSS1260-474-KLB  
MSS1260-105KL-KLB  
HI1206T161R-10  
L5  
Steward  
Bead Inductor, 160, 6A  
Cap, Film, X2Y2, 12.5MM, 250VAC, 20%, 10  
nF  
C1, C2, C15  
Panasonic  
ECQ-U2A103ML  
1
2
2
1
1
1
1
2
4
1
1
1
1
1
2
2
1
1
2
1
1
1
C4  
C5, C6  
C7, C9  
C10  
Cap, X7R, 0603, 16V, 10%, 100 nF  
Cap, X5R, 1210, 25V, 10%, 22 µF  
Cap, AL, 200V, 105C, 20%, 33 µF  
Cap, Film, 250V, 5%, 10 nF  
Cap, X7R, 1206, 50V, 10%, 1.0 uF  
Cap, C0G, 0603, 100V, 5%, 120 pF  
Diode, ZNR, SOT23, 15V, 5%  
Diode, SCH, SOD123, 40V, 120 mA  
Diode, FR, SOD123, 200V, 1A  
Diode, FR, SMB, 400V, 1A  
MuRata  
MuRata  
UCC  
GRM188R71C104KA01D  
GRM32ER61E226KE15L  
EKXG201ELL330MK20S  
B32521C3103J  
Epcos  
C12  
Kemet  
C1206F105K5RACTU  
GRM1885C2A121JA01D  
BZX84C15LT1G  
BAS40H  
C11  
MuRata  
OnSemi  
NXP  
D1  
D2, D13  
D3, D4, D8, D9  
D10  
Rohm  
RF071M2S  
OnSemi  
Fairchild  
Panasonic  
Panasonic  
Panasonic  
Rohm  
MURS140T3G  
D12  
TVS, VBR = 144V  
SMBJ130CA  
R2  
ERJ-8ENF1003V  
ERJ-14RQJ1R8U  
ERJ-3EKF5763V  
MCR10EZHF1004  
RC1206JR-070RL  
Resistor, 1206, 1%, 100 kΩ  
Resistor, 1210, 5%, 1.8Ω  
Resistor, 0603, 1%, 576 kΩ  
Resistor, 0805, 1%, 1.00 MΩ  
Resistor, 1206, 0.0Ω  
R3  
R4  
R6, R7  
R8, R10  
R9  
Yageo  
Resistor, 1812, 0.0Ω  
RT1  
Thermometrics  
Fairchild  
CL-140  
FQD7N30TF  
MMBTA92  
1715721  
Thermistor, 120V, 1.1A, 50Ω @ 25°C  
XSTR, NFET, DPAK, 300V, 4A  
XSTR, PNP, SOT23, 300V, 500 mA  
Terminal Block 2 pos  
Q1, Q2  
Q3  
Fairchild  
J1  
Phoenix Contact  
bel  
F1  
Fuse, 125V, 1,25A  
SSQ 1.25  
www.ti.com  
16  
Physical Dimensions inches (millimeters) unless otherwise noted  
MSOP-10 Pin Package (MM)  
For Ordering, Refer to Ordering Information Table  
NS Package Number MUB10A  
SOIC-8 Pin Package (M)  
For Ordering, Refer to Ordering Information Table  
NS Package Number M08A  
17  
www.ti.com  
Notes  
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Copyright © 2011, Texas Instruments Incorporated  
LM3444  
Application Note 2097 LM3444 - 230VAC, 8W Isolated Flyback LED Driver  
Literature Number: SNVA462E  
National Semiconductor  
Application Note 2097  
Clinton Jensen  
LM3444 - 230VAC, 8W  
Isolated Flyback LED Driver  
May 3, 2011  
Introduction  
Key Features  
This demonstration board highlights the performance of a  
LM3444 based Flyback LED driver solution that can be used  
to power a single LED string consisting of 4 to 10 series con-  
nected LEDs from an 180 VRMS to 265 VRMS, 50 Hz input  
power supply. The key performance characteristics under  
typical operating conditions are summarized in this applica-  
tion note.  
Line injection circuitry enables PFC values greater than  
0.98  
Adjustable LED current and switching frequency  
Flicker free operation  
Applications  
Solid State Lighting  
Industrial and Commercial Lighting  
Residential Lighting  
This is a four-layer board using the bottom and top layer for  
component placement. The demonstration board can be  
modified to adjust the LED forward current, the number of se-  
ries connected LEDs that are driven and the switching fre-  
quency. Refer to the LM3444 datasheet for detailed instruc-  
tions.  
A bill of materials is included that describes the parts used on  
this demonstration board. A schematic and layout have also  
been included along with measured performance character-  
istics.  
Performance Specifications  
Based on an LED Vf = 3.6V  
Symbol  
VIN  
Parameter  
Input voltage  
Min  
Typ  
230 VRMS  
21.5 V  
Max  
180 VRMS  
265 VRMS  
VOUT  
ILED  
POUT  
fsw  
LED string voltage  
LED string average current  
Output power  
13 V  
36 V  
-
-
-
350 mA  
7.5 W  
-
-
-
Switching frequency  
67 kHz  
Demo Board  
30139704  
© 2011 National Semiconductor Corporation  
301397  
www.national.com  
LM3444 230VAC, 8W Isolated Flyback LED Driver Demo Board Schematic  
30139701  
Warning:  
Warning:  
The LM3444 evaluation board has exposed high voltage components that present a shock hazard. Caution must be taken when handling the evaluation  
board. Avoid touching the evaluation board and removing any cables while the evaluation board is operating.  
The ground connection on the evaluation board is NOT referenced to earth ground. If an oscilloscope ground lead is connected to the evaluation  
board ground test point for analysis and the mains AC power is applied (without any isolation), the fuse (F1) will fail open. For bench evaluation, either  
the input AC power source or the bench measurement equipment should be isolated from the earth ground connection. Isolating the evaliation board  
(using 1:1 line isolation transformer) rather than the oscilloscope is highly recommended.  
Warning:  
The LM3444 evaluation board should not be powered with an open load. For proper operation, ensure that the desired number of LEDs are connected  
at the output before applying power to the evaluation board.  
www.national.com  
2
LM3444 Device Pin-Out  
30139702  
Pin Descriptions – 10 Pin MSOP  
Pin #  
Name  
NC  
Description  
1
2
3
4
No internal connection.  
No internal connection.  
No internal connection.  
NC  
NC  
COFF  
OFF time setting pin. A user set current and capacitor connected from the output to this pin sets the constant OFF  
time of the switching controller.  
5
6
7
FILTER Filter input. A capacitor tied to this pin filters the error amplifier. Could also be used as an analog dimming input.  
GND  
ISNS  
Circuit ground connection.  
LED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND to set the maximum  
LED current.  
8
GATE  
Power MOSFET driver pin. This output provides the gate drive for the power switching MOSFET of the buck  
controller.  
9
VCC  
NC  
Input voltage pin. This pin provides the power for the internal control circuitry and gate driver.  
No internal connection.  
10  
3
www.national.com  
Bill of Materials  
Designator  
Description  
Manufacturer  
National  
Semiconductor  
Part Number  
LM3444MM  
RoHS  
U1  
C1  
Offline LED Driver, PowerWise  
Ceramic, X7R, 250VAC, 10%  
Y
Murata Electronics  
North America  
DE1E3KX332MA5BA01  
Y
C2  
C3  
C4  
Ceramic, Polypropylene, 400VDC, 10%  
CAP, CERM, 330pF, 630V, +/-5%, C0G/NP0, 1206  
Ceramic, X7R, 250V, X2, 10%, 2220  
WIMA  
TDK  
MKP10-.033/400/5P10  
C3216C0G2J331J  
Y
Y
Y
Murata Electronics  
North America  
GA355DR7GF472KW01L  
C5  
C9, C11  
C10  
CAP, Film, 0.033µF, 630V, +/-10%, TH  
EPCOS Inc  
MuRata  
B32921C3333K  
Y
Y
Y
Y
Y
Y
Y
CAP, CERM, 1µF, 50V, +/-10%, X7R, 1210  
CAP, CERM, 0.47µF, 50V, +/-10%, X7R, 0805  
Aluminium Electrolytic, 680uF, 35V, 20%,  
CAP, CERM, 1µF, 35V, +/-10%, X7R, 0805  
CAP, CERM, 0.1µF, 25V, +/-10%, X7R, 0603  
GRM32RR71H105KA01L  
GRM21BR71H474KA88L  
UHE1V681MHD6  
MuRata  
C12  
Nichicon  
Taiyo Yuden  
MuRata  
C13  
GMK212B7105KG-T  
GRM188R71E104KA01D  
TPSC476K016R0350  
C14  
C15  
CAP, TANT, 47uF, 16V, +/-10%, 0.35 ohm, 6032-28 AVX  
SMD  
C18  
C20  
CAP, CERM, 2200pF, 50V, +/-10%, X7R, 0603  
CAP, CERM, 330pF, 50V, +/-5%, C0G/NP0, 0603  
DIODE TVS 250V 600W UNI 5% SMD  
Diode, Switching-Bridge, 600V, 0.8A, MiniDIP  
Diode, Silicon, 1000V, 1A, SOD-123  
MuRata  
GRM188R71H222KA01D  
GRM1885C1H331JA01D  
P6SMB250A  
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
MuRata  
D1  
Littelfuse  
Diodes Inc.  
D2  
HD06-T  
D3  
Comchip Technology CGRM4007-G  
STMicroelectronics STPS1H100A  
D4  
Diode, Schottky, 100V, 1A, SMA  
D5, D10  
D6  
Diode, Zener, 13V, 200mW, SOD-323  
Diode, Zener, 36V, 550mW, SMB  
Diodes Inc  
DDZ13BS-7  
ON Semiconductor  
1SMB5938BT3G  
D7, D8, D9  
F1  
Diode, Schottky, 100V, 150 mA, SOD-323  
Fuse, 500mA, 250V, Time-Lag, SMT  
STMicroelectronics BAT46JFILM  
Littelfuse Inc  
Keystone  
0443.500DR  
1902C  
H1, H2, H5, H6 Standoff, Hex, 0.5"L #4-40 Nylon  
H3, H4, H7, H8 Machine Screw, Round, #4-40 x 1/4, Nylon, Philips  
panhead  
B&F Fastener Supply NY PMS 440 0025 PH  
J1, J2  
L1, L2  
Conn Term Block, 2POS, 5.08mm PCB  
Phoenix Contact  
TDK Corporation  
1715721  
Y
Y
Inductor, Radial Lead Inductors, Shielded, 4.7mH,  
130mA, 12.20ohm, 7.5mm Radial,  
TSL080RA-472JR13-PF  
LED+, LED-, Terminal, 22 Gauge Wire, Terminal, 22 Guage Wire 3M  
TP7, TP8  
923345-02-C  
Y
Y
Q1  
MOSFET, N-CH, 600V, 200mA, SOT-223  
Fairchild  
FQT1N60CTF_WS  
Semiconductor  
Q2  
Q3  
Transistor, NPN, 300V, 500mA, SOT-23  
MOSFET, N-CH, 650V, 800mA, IPAK  
Diodes Inc.  
MMBTA42-7-F  
SPU01N60C3  
Y
Y
Infineon  
Technologies  
R1  
R2, R7  
R3, R8  
R4, R12  
R13  
RES, 221 ohm, 1%, 0.25W, 1206  
RES, 200k ohm, 1%, 0.25W, 1206  
RES, 309k ohm, 1%, 0.25W, 1206  
RES, 10k ohm, 5%, 0.25W, 1206  
RES, 33.0 ohm, 1%, 0.25W, 1206  
RES, 10 ohm, 5%, 0.125W, 0805  
RES, 10.0k ohm, 1%, 0.1W, 0603  
RES, 10 ohm, 5%, 0.1W, 0603  
RES, 1.91k ohm, 1%, 0.1W, 0603  
RES, 2.70 ohm, 1%, 0.25W, 1206  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Panasonic  
CRCW1206221RFKEA  
CRCW1206200KFKEA  
CRCW1206309KFKEA  
CRCW120610K0JNEA  
CRCW120633R0FKEA  
CRCW080510R0JNEA  
CRCW060310K0FKEA  
CRCW060310R0JNEA  
CRCW06031K91FKEA  
ERJ-8RQF2R7V  
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
R14  
R15  
R19  
R20  
R21  
www.national.com  
4
Designator  
R22  
Description  
Manufacturer  
Vishay-Dale  
Part Number  
CRCW080510R7FKEA  
CRCW0603324KFKEA  
MF72-060D5  
RoHS  
RES, 10.7 ohm, 1%, 0.125W, 0805  
RES, 324k ohm, 1%, 0.1W, 0603  
Y
Y
Y
Y
Y
Y
R23  
Vishay-Dale  
Cantherm  
RT1  
Current Limitor Inrush, 60Ohm, 20%, 5mm Raidal  
FLBK TFR, 2.07 mH, Np=140T, Ns=26T, Na= 20T  
Terminal, Turret, TH, Double  
T1  
Wurth Elektornik  
750815040 REV 1  
TP9, TP10  
VR1  
Keystone Electronics 1502-2  
EPCOS Inc S10K275E2  
Varistor 275V 55J 10mm DISC  
5
www.national.com  
Transformer Design  
Mfg: Wurth Electronics, Part #: 750815040 Rev. 01  
30139709  
Parameter  
Test Conditions  
20°C  
Value  
D.C. Resistance (3-1)  
D.C. Resistance (6-4)  
D.C. Resistance (10-13)  
Inductance (3-1)  
1.91 Ω ± 10%  
0.36 Ω ± 10%  
20°C  
20°C  
0.12 Ω ± 10%  
10 kHz, 100 mVAC  
10 kHz, 100 mVAC  
10 kHz, 100 mVAC  
2.12 mH ± 10%  
46.50 µH ± 10%  
74.00 µH ± 10%  
18.0 µH Typ., 22.60 µH Max.  
4500 VAC, 1 minute  
7:1 ± 1%  
Inductance (6-4)  
Inductance (10-13)  
Leakage Inductance (3-1)  
Dielectric (1-13)  
Turns Ratio  
100 kHz, 100 mAVAC (tie 6+4, 10+13)  
tie (3+4), 4500 VAC, 1 second  
(3-1):(6-4)  
Turns Ratio  
(3-1):(10:13)  
5.384:1 ± 1%  
www.national.com  
6
Demo Board Wiring Overview  
30139703  
Wiring Connection Diagram  
Test Point  
Name  
I/O  
Description  
LED Constant Current Supply  
TP10, J2-1  
LED +  
Output  
Supplies voltage and constant-current to anode of LED string.  
TP9, J2-2  
J1-1  
LED -  
LINE  
Output  
Input  
LED Return Connection (not GND)  
Connects to cathode of LED string. Do NOT connect to GND.  
AC Line Voltage  
Connects directly to AC line of a 230VAC system.  
J1-2  
NEUTRAL  
Input  
AC Neutral  
Connects directly to AC neutral of a 230VAC system.  
Demo Board Assembly  
30139705  
Top View  
30139706  
Bottom View  
7
www.national.com  
Typical Performance Characteristics (Note 1, Note 2, Note 3)  
Efficiency vs. Line Voltage  
Original Circuit  
Efficiency vs. Line Voltage  
Modified Circuits  
0.97  
0.93  
0.89  
0.85  
0.81  
0.77  
0.73  
0.68  
0.64  
0.60  
Mod C (10 LEDs)  
10 LEDs  
8 LEDs  
0.87  
0.85  
0.82  
0.80  
0.78  
Mod B (8 LEDs)  
6 LEDs  
4 LEDs  
Original (6 LEDs)  
Mod A (4 LEDs)  
180 190 200 210 220 230 240 250 260  
INPUT VOLTAGE (V  
180 190 200 210 220 230 240 250 260  
INPUT VOLTAGE (V  
)
)
RMS  
RMS  
30139710  
30139714  
LED Current vs. Line Voltage  
Original Circuit  
LED Current vs. Line Voltage  
Modified Circuits  
650  
550  
450  
350  
250  
150  
50  
600  
550  
500  
450  
400  
350  
300  
250  
200  
150  
100  
Mod C (10 LEDs)  
Mod B (8 LEDs)  
4 LEDs  
6 LEDs  
Original (6 LEDs)  
Mod A (4 LEDs)  
8 LEDs  
10 LEDs  
180 190 200 210 220 230 240 250 260  
INPUT VOLTAGE (V  
180 190 200 210 220 230 240 250 260  
INPUT VOLTAGE (V  
)
)
RMS  
RMS  
30139711  
30139715  
www.national.com  
8
Power Factor vs. Line Voltage  
Output Power vs. Line Voltage  
Original Circuit  
1.000  
0.995  
0.990  
0.985  
0.980  
0.975  
0.970  
0.965  
0.960  
0.955  
0.950  
12  
11  
10  
9
10 LEDs  
8 LEDs  
4 LEDs  
8
7
6 LEDs  
6
5
4
3
2
180 190 200 210 220 230 240 250 260  
180 190 200 210 220 230 240 250 260  
LINE VOLTAGE (V  
)
RMS  
INPUT VOLTAGE (V  
)
RMS  
30139713  
30139712  
Output Power vs. Line Voltage  
Modified Circuits  
Line Voltage and Line Current  
(VIN = 230VRMS, 6 LEDs, ILED = 350mA)  
25.0  
22.5  
20.0  
17.5  
Mod B (8 LEDs)  
15.0 Mod C (10 LEDs)  
12.5  
10.0  
7.5  
5.0  
2.5  
Mod A (4 LEDs)  
Original (6 LEDs)  
0.0  
Ch1: Line Voltage (100 V/div); Ch3: Line C3u01r3r9e71n8t  
(20 mA/div); Time (4 ms/div)  
180 190 200 210 220 230 240 250 260  
INPUT VOLTAGE (V  
RMS  
)
30139717  
Output Voltage and LED Current  
(VIN = 230VRMS, 6 LEDs, ILED = 350mA)  
Power MOSFET Drain and ISNS (Pin-7) Voltage  
(VIN = 230VRMS, 6 LEDs, ILED = 350mA)  
30139720  
30139721  
Ch1: Output Voltage (10 V/div); Ch3: LED Current  
(100 mA/div); Time (4 ms/div)  
Ch1: Drain Voltage (100V/div); Ch4: ISNS Voltage  
(500 mV/div); Time (4 µs/div)  
9
www.national.com  
FILTER (Pin-5) and ISNS (Pin-7) Voltage  
(VIN=230VRMS, 6 LEDs, ILED = 350mA  
30139722  
Ch1: FILTER Voltage (200 mV/div); ISNS Voltage  
(200 mV/div); Time (4 µs/div)  
Note 1: Original Circuit (6 LEDs operating at 350mA): R21 = 2.7; Modification A (10 LEDs operating at 375mA): R21 = 1.8; Modification B (8 LEDs operating  
at 350mA): R21 = 2.2; Modification C (4 LEDs operating at 315mA): R21 = 3.9Ω  
Note 2: The output power can be varied to achieve desired LED current by interpolating R21 values between the maximum of 3.9 and minimum of 1.8 Ω  
Note 3: The maximum output voltage is clamped to 36 V. For operating LED string voltage > 36 V, replace D6 with suitable alternative  
PCB Layout  
30139707  
Top Layer  
www.national.com  
10  
 
 
 
30139740  
Top Middle Layer  
30139741  
Bottom Middle Layer  
11  
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30139708  
Bottom Layer  
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12  
mA. The 100 Hz current ripple flowing through the LED string  
was measured to be 194 mApk-pk at full load. The magnitude  
of the ripple is a function of the value of energy storage ca-  
pacitors connected across the output. The ripple current can  
be reduced by increasing the value of energy storage capac-  
itor or by increasing the LED string voltage.  
Experimental Results  
The LED driver is designed to accurately emulate an incan-  
descent light bulb and therefore behave as an emulated  
resistor. The resistor value is determined based on the LED  
string configuration and the desired output power. The circuit  
then operates in open-loop, with a fixed duty cycle based on  
a constant on-time and constant off-time that is set by select-  
ing appropriate circuit components.  
The LED driver switching frequency is measured to be close  
to the specified 67 kHz. The circuit operates with a constant  
duty cycle of 0.21 and consumes near 9W of input power. The  
driver steady state performance for an LED string consisting  
of 6 series LEDs is summarized in the following table.  
PERFORMANCE  
In steady state, the LED string voltage is measured to be  
21.55 V and the average LED current is measured as 347.5  
MEASURED EFFICIENCY AND LINE REGULATION (6 LEDS)  
PIN(W) VOUT (V) ILED (mA) POUT (W)  
5.42 20.59 219.40 4.52  
VIN (VRMS  
180  
)
IIN (mARMS  
30.65  
)
Efficiency (%) Power Factor  
83.3  
83.3  
83.2  
83.2  
83.3  
83.6  
83.6  
83.5  
83.3  
0.9867  
0.9869  
0.9870  
0.9871  
0.9872  
0.9873  
0.9874  
0.9875  
0.9877  
190  
32.35  
6.06  
6.75  
7.47  
8.20  
8.96  
9.76  
10.62  
11.57  
20.80  
21.00  
21.18  
21.37  
21.55  
21.72  
21.90  
22.07  
242.55  
267.37  
293.39  
320.18  
347.51  
375.52  
404.82  
436.75  
5.05  
5.62  
6.21  
6.84  
7.49  
8.15  
8.86  
9.64  
200  
34.21  
210  
36.01  
220  
37.74  
230  
39.44  
240  
41.22  
250  
43..29  
45.06  
260  
CURRENT THD  
the fundamental current (as shown in the following table) and  
therefore meets the requirements of the IEC 61000-3-2  
Class-3 standard. Total harmonic distortion was measured to  
be less than 1.2%.  
The LED driver is able to achieve close to unity power factor  
(PF ~ 0.98) which meets Energy Star requirements. This de-  
sign also exhibits low current harmonics as a percentage of  
MEASURED HARMONIC CURRENT  
Harmonic  
Class C Limit (mA)  
Measured (mA)  
0.022  
0.125  
0.11  
2
0.78  
11.61  
3.90  
2.73  
1.95  
1.73  
1.73  
1.73  
1.73  
1.73  
1.73  
1.73  
1.73  
1.73  
1.73  
1.73  
3
5
7
0.105  
0.11  
9
11  
13  
15  
17  
19  
21  
23  
25  
27  
29  
31  
0.15  
0.093  
0.071  
0.154  
0.165  
0.065  
0.065  
0.08  
0.084  
0.065  
0.07  
13  
www.national.com  
Electromagnetic Interference (EMI)  
The EMI input filter of this evaluation board is configured as  
shown in the following circuit diagram.  
30139731  
FIGURE 1. Input EMI Filter and Rectifier Circuit  
In order to get a quick estimate of the EMI filter performance,  
only the PEAK conductive EMI scan was measured and the  
data was compared to the Class B conducted EMI limits pub-  
lished in FCC – 47, section 15.(Note 4)  
30139732  
FIGURE 2. Peak Conductive EMI scan per CISPR-22, Class B Limits  
Note 4: CISPR 15 compliance pending  
www.national.com  
14  
 
ILED = 348 mA  
Thermal Analysis  
The board temperature was measured using an IR camera  
(HIS-3000, Wahl) while running under the following condi-  
tions:  
# of LEDs = 6  
POUT = 7.2 W  
The results are shown in the following figures.  
VIN = 230 VRMS  
30139733  
FIGURE 3. Top Side Thermal Scan  
30139734  
FIGURE 4. Bottom Side Thermal Scan  
15  
www.national.com  
TER pin, the on-time can be made to be constant. With a DCM  
Flyback, Δi needs to increase as the input voltage line in-  
creases. Therefore a constant on-time (since inductor L is  
constant) can be obtained.  
Circuit Analysis and Explanations  
INJECTING LINE VOLTAGE INTO FILTER (ACHIEVING  
PFC > 0.98)  
By using the line voltage injection technique, the FILTER pin  
has the voltage wave shape shown in Figure 6 on it. Voltage  
at VFILTER peak should be kept below 1.25V. At 1.25V current  
limit is tripped. C11 is small enough not to distort the AC signal  
but adds a little filtering.  
If a small portion (750mV to 1.00V) of line voltage is injected  
at FILTER of the LM3444, the circuit is essentially turned into  
a constant power flyback as shown in Figure 5.  
Although the on-time is probably never truly constant, it can  
be observed in Figure 7 how (by adding the rectified voltage)  
the on-time is adjusted.  
30139737  
FIGURE 6. FILTER Waveform  
For this evaluation board, the following resistor values are  
used:  
R3 = R8 = 309 kΩ  
R20 = 1.91 kΩ  
Therefore the voltages observed on the FILTER pin will be as  
follows for listed input voltages:  
For VIN = 180VRMS, VFILTER, Pk = 0.78V  
For VIN = 230VRMS, VFILTER, Pk = 1.00V  
For VIN = 265VRMS, VFILTER, Pk = 1.15V  
30139735  
FIGURE 5. Line Voltage Injection Circuit  
Using this technique, a power factor greater than 0.98 can be  
achieved without additional passive active power factor con-  
trol (PFC) circuitry.  
The LM3444 works as a constant off-time controller normally,  
but by injecting the 1.0VPk rectified AC voltage into the FIL-  
30139736  
FIGURE 7. Typical Operation of FILTER Pin  
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16  
Notes  
17  
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Notes  
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LM3444  
Application Note 2083 LM3444 A19 Edison Retrofit Evaluation Board  
Literature Number: SNVA455B  
National Semiconductor  
Application Note 2083  
Clinton Jensen  
LM3444 A19 Edison Retrofit  
Evaluation Board  
December 2, 2010  
input voltage are valid only for the demonstration board as  
shipped with the schematic below. Please refer to the LM3444  
data sheet for detailed information regarding the LM3444 de-  
vice. The board is currently set up to drive five to thirteen  
series connected LEDs, but the evaluation board may be  
modified to accept more series LEDs. Refer to the tables in  
this document for modifying the board to accept more LEDs  
and/or adjust for different current levels.  
Introduction  
The evaluation board included in this shipment converts  
85VAC to 135VAC input and drives five to thirteen series con-  
nected LED’s at the currents listed in the Evaluation Board  
Operating Conditions section. This is a two-layer board using  
the bottom and top layer for component placement. The board  
is surrounded by a larger area allowing for extra test points  
and connectors for ease of evaluation. The actual board size  
is contained inside the larger outer area and can be cut out  
for the smallest size possible. The evaluation board can be  
modified to adjust the LED forward current and the number of  
series connected LEDs. The topology used for this evaluation  
board eliminates the need for passive power factor correction  
and results in high efficiency and power factor with minimal  
component count which results in a size that can fit in a stan-  
dard A19 Edison socket. Output current is regulated within  
±15% of nominal from circuit to circuit and over line voltage  
variation. Refer to the LM3444 datasheet for details on the  
LM3444 IC.  
Evalution Board Operating  
Conditions  
VIN = 85VAC to 135VAC  
5 to 13 series connected LEDs as configured with the currents  
listed below  
Can drive up to 18 series LEDs (see table)  
ILED = 340 mA (5 LEDs)  
ILED = 300 mA (7 LEDs)  
ILED = 260 mA (9 LEDs)  
A bill of materials below describes the parts used on this  
demonstration board. A schematic and layout have also been  
included below along with measured performance character-  
istics including EMI/EMC data. The above restrictions for the  
ILED = 230 mA (11 LEDs)  
ILED = 205 mA (13 LEDs)  
Simplified LM3444 Schematic  
30131201  
Warning:  
Warning:  
The LM3444 evaluation boards have no isolation or any type of protection from shock. Caution must be taken when handling evaluation board.  
Avoid touching evaluation board, and removing any cables while evaluation board is operating. Isolating the evaluation board rather than the  
oscilloscope is highly recommended.  
This LM3444 evaluation PCB is a non-isolated design. The ground connection on the evaluation board is NOT referenced to earth ground. If an  
oscilloscope ground lead is connected to the evaluation board ground test point for analysis, and AC power is applied, the fuse (F1) will fail open.  
The oscilloscope should be powered via an isolation transformer before an oscilloscope ground lead is connected to the evaluation board.  
© 2010 National Semiconductor Corporation  
301312  
www.national.com  
Pin-Out  
30131203  
10-Pin MSOP  
Pin Description 10 Pin MSOP  
Pin #  
Name  
Description  
1
2
3
4
NC  
NC  
No internal connection.  
No internal connection.  
No internal connection.  
NC  
COFF  
OFF time setting pin. A user set current and capacitor connected from the output to this pin sets the constant  
OFF time of the switching controller.  
5
FILTER  
Filter input. A capacitor tied to this pin filters the error amplifier. Could also be used as an analog dimming  
input.  
6
7
GND  
ISNS  
Circuit ground connection.  
LED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND to set the  
maximum LED current.  
8
GATE  
Power MOSFET driver pin. This output provides the gate drive for the power switching MOSFET of the buck  
controller.  
9
VCC  
NC  
Input voltage pin. This pin provides the power for the internal control circuitry and gate driver.  
No internal connection.  
10  
www.national.com  
2
30131207  
A N - 2 0 8  
Bill of Materials LM3444 Evaluation Board  
REF DES  
Description  
IC DRIVER LED 10MSOP  
MFG  
MFG Part Number  
LM3444MM  
U1  
National Semiconductor  
Johanson Dielectrics  
Vishay/BC Components  
Nichicon  
C1, C10  
Ceramic, 47000pF, 500V, X7R, 1210  
CAP FILM MKP .0047µF 310VAC X2  
CAP 470µF 50V ELECT PW RADIAL  
DNP  
501S41W473KV4E  
BFC233820472  
UPW1H471MHD  
C2  
C3  
C4/RBLDR (Note 1)  
C5  
Ceramic, .33µF, 250V, X7R, 1812  
CAP .10µF 305VAC EMI SUPPRESSION  
Ceramic, 47µF, X5R, 16V, 1210  
Ceramic, 470pF, 50V, X7R, 0603  
Ceramic, 0.1µF, 16V, X7R, 0603  
Ceramic, 0.47µF, 16V, X7R, 0603  
DIODE SCHOTTKY 1A 200V PWRDI 123  
Bridge Rectifier, Vr = 400V, Io = 0.8A, Vf = 1V  
DIODE FAST 1A 300V SMA  
TDK Corporation  
EPCOS  
C4532X7R2E334K  
B32921C3104M  
GRM32ER61C476ME15L  
GRM188R71H471KA01D  
GRM188R71C104KA01D  
GRM188R71C474KA88D  
DFLS1200-7  
C6  
C8  
MuRata  
C12  
MuRata  
C15  
MuRata  
C14  
MuRata  
D1  
Diodes Inc.  
D2  
Diodes Inc.  
HD04-T  
D4  
Fairchild Semi conductor  
Fairchild Semi conductor  
Diodes Inc.  
ES1F  
D7  
DIODE ZENER 15V 500MW SOD-123  
DIODE SCHOTTKY 1A 200V PWRDI 123  
FUSE 1A 125V FAST  
MMSZ5245B  
D8  
DFLS1200-7  
F1  
Cooper/Bussman  
Tyco Electronics  
J.W. Miller/Bourns  
Coilcraft Inc.  
3M  
6125FA1A  
J5, J10  
CONN HEADER .312 VERT 2POS TIN  
INDUCTOR 3900µH .12A RADIAL  
820µH, Shielded Drum Core  
1-1318301-2  
L1, L2  
RL875S-392K-RC  
MSS1038-824KL  
923345-03-C  
L3  
M1  
JUMPER WIRE 0.3" J6 TO J1  
JUMPER WIRE 0.3" J7 to J4  
JUMPER WIRE 0.3" J2 TO J8  
JUMPER WIRE 0.3" J3 TO J9  
MOSFET N-CH 240V 260MA SOT-89  
MOSFET N-CH 250V 4.4A DPAK  
RES 200k, 0.25W, 1%, 1206  
RES 274k, 0.25W, 1%, 1206  
RES 430, 1/2W, 5%, 2010  
M2  
3M  
923345-03-C  
M3  
3M  
923345-03-C  
M4  
3M  
923345-03-C  
Q1  
Infineon Technologies  
Fairchild Semi conductor  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
BSS87 L6327  
Q2  
FDD6N25TM  
R1, R3  
CRCW1206200kFKEA  
CRCW1206274kFKEA  
CRCW2010430RJNEF  
CRCW120630k1FKEA  
R2, R7  
R4  
R6, R24  
RES 30.1k, 0.25W, 1%, 1206  
DNP  
R10  
R12  
Vishay-Dale  
Vishay-Dale  
CRCW06034R70JNEA  
CRCW12083R54FNEA  
CRCW06033K16FKEA  
CRCW0603255KFKEA  
CRCW080540R2FKEA  
MF72-060D5  
RES 4.7, 0.1W, 5%, 0603  
R14  
RES 1.54, 1/4W, 1%, 1206  
RES 3.16k, 0.1w, 1%, 0603  
RES 255k, 0.1W, 1%, 0603  
RES 40.2, 0.125W, 1%, 0805  
CURRENT LIMITOR INRUSH 60Ω 20%  
Terminal, Turret, TH, Double  
R15  
Vishay-Dale  
R16  
Vishay-Dale  
R22  
RT1  
Vishay-Dale  
Cantherm  
TP1, TP2, TP3, TP4  
Keystone Electronics  
1502-2  
Note 1: C4/RBLDR is a dual purpose pad which is unpopulated by default. A ceramic capacitor (C4) may be used here if extra high frequency bypassing is desired  
across the LED load. Alternatively a bleeder resistor (RBLDR) in the range of 10kto 100kmay be placed here to quickly discharge C3 and prevent prolonged  
LED glow due to the energy stored in C3.  
www.national.com  
4
 
Output Current versus Number of LEDs for Various Modifications  
# of LEDs  
Output Current (mA)  
Original Circuit  
Output Current (mA)  
Modification A (Note 2)  
Output Current (mA)  
Modification B (Note 3)  
Output Current (mA)  
Modification C (Note 4)  
2
520  
500  
475  
455  
432  
412  
3
4
5
340  
315  
300  
275  
260  
245  
230  
215  
205  
196  
190  
183  
175  
170  
248  
235  
222  
210  
200  
190  
180  
170  
164  
156  
150  
142  
135  
130  
265  
250  
237  
224  
212  
200  
190  
180  
170  
162  
155  
148  
142  
137  
6
7
8
9
10  
11  
12  
13  
14 (Note 5)  
15 (Note 5)  
16 (Note 5)  
17 (Note 5)  
18 (Note 5)  
Note 2: Modification A: R14 = 2.37, R16 = 150k, C3 = 330µF, 63V.  
Note 3: Modification B: R14 = 2.2, R16 = 165kΩ.  
Note 4: Modification C: R14 = 1.2, R16 = 137k, L3 = 470µH, C3 = 1000µF, 25V.  
Note 5: For all applications using greater than 13 LEDs a 330µF, 63V output capacitor (C3) was used.  
5
www.national.com  
 
 
 
 
Typical Performance Characteristics  
Efficiency vs. Line Voltage  
Original Circuit  
Power Factor vs. Line Voltage  
Original Circuit  
30131202  
30131204  
Efficiency vs. Line Voltage  
Modification A  
Power Factor vs. Line Voltage  
Modification A  
30131211  
30131212  
Efficiency vs. Line Voltage  
Modification B  
Power Factor vs. Line Voltage  
Modification B  
30131213  
30131214  
www.national.com  
6
PCB Layout  
30131210  
Top Layer  
30131209  
Bottom Layer  
Warning:  
The LM3444 evaluation boards have no isolation or any type of protection from shock. Caution must be taken when handling evaluation board. Avoid  
touching evaluation board, and removing any cables while evaluation board is operating. Isolating the evaluation board rather than the oscilloscope  
is highly recommended.  
7
www.national.com  
EMI/EMC Information  
30131215  
Radiated EMI  
30131216  
Conducted EMC. Line = Blue, Neutral = Black.  
Frequency  
Quasi-peak  
Amplitude  
Quasi-peak  
Limit  
Quasi-peak  
Delta  
Average  
Amplitude  
Average Limit  
Average  
Delta  
Neutral  
Line  
154 kHz  
1.1 MHz  
57  
66  
-9  
47  
31  
56  
46  
-9  
-15  
www.national.com  
8
Notes  
9
www.national.com  
Notes  
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LM3444  
Application Note 2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver  
Literature Number: SNVA454D  
National Semiconductor  
Application Note 2082  
Clinton Jensen  
LM3444 -120VAC, 8W  
Isolated Flyback LED Driver  
December 7, 2010  
Introduction  
Key Features  
This demonstration board highlights the performance of a  
LM3444 based Flyback LED driver solution that can be used  
to power a single LED string consisting of 4 to 8 series con-  
nected LEDs from an 90 VRMS to 135 VRMS, 60 Hz input power  
supply. The key performance characteristics under typical  
operating conditions are summarized in this application note.  
Line injection circuitry enables PFC values greater than  
0.99  
Adjustable LED current and switching frequency  
Flicker free operation  
Applications  
This is a two-layer board using the bottom and top layer for  
component placement. The demonstration board can be  
modified to adjust the LED forward current, the number of se-  
ries connected LEDs that are driven and the switching fre-  
quency. Refer to the LM3444 datasheet for detailed instruc-  
tions.  
Solid State Lighting  
Industrial and Commercial Lighting  
Residential Lighting  
A bill of materials is included that describes the parts used on  
this demonstration board. A schematic and layout have also  
been included along with measured performance character-  
istics.  
Performance Specifications  
Based on an LED Vf = 3.57V  
Symbol  
VIN  
Parameter  
Input voltage  
Min  
Typ  
120 VRMS  
21.4 V  
Max  
90 VRMS  
135 VRMS  
VOUT  
ILED  
POUT  
fsw  
LED string voltage  
LED string average current  
Output power  
12 V  
30 V  
-
-
-
350 mA  
7.6 W  
-
-
-
Switching frequency  
79 kHz  
Demo Board  
30131168  
© 2010 National Semiconductor Corporation  
301311  
www.national.com  
LM3444 120VAC, 8W Isolated Flyback LED Driver Demo Board Schematic  
30131101  
Warning:  
Warning:  
Warning:  
The LM3444 evaluation board has exposed high voltage components that present a shock hazard. Caution must be taken when handling the evaluation  
board. Avoid touching the evaluation board and removing any cables while the evaluation board is operating. Isolating the evaluation board rather  
than the oscilloscope is highly recommended.  
The ground connection on the evaluation board is NOT referenced to earth ground. If an oscilloscope ground lead is connected to the evaluation  
board ground test point for analysis and AC power is applied, the fuse (F1) will fail open. The oscilloscope should be powered via an isolation  
transformer before an oscilloscope ground lead is connected to the evaluation board.  
The LM3444 evaluation board should not be powered with an open load. For proper operation, ensure that the desired number of LEDs are connected  
at the output before applying power to the evaluation board.  
www.national.com  
2
LM3444 Device Pin-Out  
30131102  
Pin Description 10 Pin MSOP  
Pin #  
Name  
NC  
Description  
1
2
3
4
No internal connection.  
No internal connection.  
No internal connection.  
NC  
NC  
COFF  
OFF time setting pin. A user set current and capacitor connected from the output to this pin sets the constant OFF  
time of the switching controller.  
5
6
7
FILTER Filter input. A capacitor tied to this pin filters the error amplifier. Could also be used as an analog dimming input.  
GND  
ISNS  
Circuit ground connection.  
LED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND to set the maximum  
LED current.  
8
GATE  
Power MOSFET driver pin. This output provides the gate drive for the power switching MOSFET of the buck  
controller.  
9
VCC  
NC  
Input voltage pin. This pin provides the power for the internal control circuitry and gate driver.  
No internal connection.  
10  
3
www.national.com  
Bill of Materials  
Designator  
Description  
Manufacturer  
Part Number  
551600530-001A  
AA1  
Printed Circuit Board  
-
C1  
C2  
CAP .047UF 630V METAL POLYPRO  
CAP 10000PF X7R 250VAC X2 2220  
CAP 330UF 35V ELECT PW  
EPCOS Inc  
B32559C6473K000  
GA355DR7GB103KY02L  
UPW1V331MPD6  
B32921C3104M  
Murata Electronics North America  
C3, C4  
C6  
Nichicon  
EPCOS  
Kemet  
CAP .10UF 305VAC EMI SUPPRESSION  
C7  
CAP, CERM, 0.1µF, 16V, +/-10%, X7R,  
0805  
C0805C104K4RACTU  
C8  
C11  
C12  
C13  
D1  
CAP CER 47UF 16V X5R 1210  
CAP CER 2200PF 50V 10% X7R 0603  
CAP CER 330PF 50V 5% C0G 0603  
CAP CER 2200PF 250VAC X1Y1 RAD  
DIODE TVS 150V 600W UNI 5% SMB  
RECT BRIDGE GP 600V 0.5A MINIDIP  
DIODE RECT GP 1A 1000V MINI-SMA  
DIODE SCHOTTKY 100V 1A SMA  
DIODE ZENER 30V 1.5W SMA  
MuRata  
MuRata  
GRM32ER61C476ME15L  
GRM188R71H222KA01D  
GRM1885C1H331JA01D  
CD12-E2GA222MYNS  
SMAJ120A  
MuRata  
TDK Corporation  
Littlefuse  
D2  
Diodes Inc.  
RH06-T  
D3  
Comchip Technology  
ST Microelectronics  
ON Semiconductor  
Fairchild Semiconductor  
Diode Inc  
CGRM4007-G  
D4  
STPS1H100A  
D5  
1SMA5936BT3G  
MM5Z12V  
D7  
DIODE ZENER 12V 200MW  
D8  
DIODE SWITCH 200V 200MW  
BAV20WS-7-F  
6125FA  
F1  
FUSE BRICK 1A 125V FAST 6125FA  
Cooper/Bussmann  
3M  
J1, J2, J3, J4, TP8, 16 GA WIRE HOLE, 18 GA WIRE HOLE  
TP9, TP10  
923345-02-C  
J5, J6  
L1, L2  
Q1  
CONN HEADER .312 VERT 2POS TIN  
INDUCTOR 4700UH .13A RADIAL  
MOSFET N-CH 600V 90MA SOT-89  
MOSFET N-CH 600V 1.8A TO-251  
RES 200K OHM 1/4W 5% 1206 SMD  
RES, 309k ohm, 1%, 0.25W, 1206  
RES, 10.5k ohm, 1%, 0.125W, 0805  
RES 4.7 OHM 1/10W 5% 0603 SMD  
RES 10 OHM 1/8W 5% 0805 SMD  
RES 1.50 OHM 1/4W 1% 1206 SMD  
RES 3.48K OHM 1/10W 1% 0603 SMD  
RES 191K OHM 1/10W 1% 0603 SMD  
RES 40.2 OHM 1/8W 1% 0805 SMD  
CURRENT LIMITOR INRUSH 60OHM 20%  
Transformer  
Tyco Electronics  
TDK Corporation  
Infineon Technologies  
Infineon Technology  
Vishay-Dale  
1-1318301-2  
TSL0808RA-472JR13-PF  
BSS225 L6327  
Q2  
SPU02N60S5  
R1, R3  
R2, R7  
R6, R24  
R12  
CRCW1206200KJNEA  
CRCW1206309KFKEA  
CRCW080510K5FKEA  
CRCW06034R70JNEA  
CRCW080510R0JNEA  
CRCW12061R50FNEA  
CRCW06033K48FKEA  
CRCW0603191KFKEA  
CRCW080540R2FKEA  
MF72-060D5  
Vishay-Dale  
Vishay-Dale  
Vishay-Dale  
R13  
Vishay-Dale  
R14  
Vishay-Dale  
R15  
Vishay-Dale  
R16  
Vishay-Dale  
R22  
Vishay-Dale  
RT1  
Cantherm  
T1  
Wurth Electronics  
Keystone Electronics  
-
750311553 Rev. 01  
1502-2  
TP2-TP5  
TP7  
Terminal, Turret, TH, Double  
TEST POINT ICT  
-
U1  
Offline LED Driver, PowerWise  
National Semiconductor  
LM3444MM  
www.national.com  
4
Demo Board Wiring Overview  
30131143  
Wiring Connection Diagram  
Test Point  
Name  
I/O  
Description  
LED Constant Current Supply  
TP3  
LED +  
Output  
Supplies voltage and constant-current to anode of LED string.  
TP2  
TP5  
TP4  
LED -  
LINE  
Output  
Input  
LED Return Connection (not GND)  
Connects to cathode of LED string. Do NOT connect to GND.  
AC Line Voltage  
Connects directly to AC line of a 120VAC system.  
NEUTRAL  
Input  
AC Neutral  
Connects directly to AC neutral of a 120VAC system.  
Demo Board Assembly  
30131169  
Top View  
30131170  
Bottom View  
5
www.national.com  
Typical Performance Characteristics (Note 1)  
Efficiency vs. Line Voltage  
Original Circuit  
Efficiency vs. Line Voltage  
Modified Circuits  
86  
86  
84  
82  
80  
78  
76  
84  
Original  
Mod A  
8 LEDs  
82  
6 LEDs  
80  
Mod B  
Mod C  
4 LEDs  
78  
76  
80  
90  
100 110 120 130 140  
80  
90  
100 110 120 130 140  
LINE VOLTAGE (V  
)
LINE VOLTAGE (V )  
RMS  
RMS  
30131187  
30131189  
30131191  
30131188  
30131190  
30131193  
LED Current vs. Line Voltage  
Original Circuit  
LED Current vs. Line Voltage  
Modified Circuits  
1.0  
0.8  
0.7  
0.4  
0.2  
0.0  
1.0  
0.8  
0.7  
0.4  
0.2  
0.0  
Mod C  
Mod B  
6 LEDs  
4 LEDs  
Mod A  
8 LEDs  
Original  
80  
90  
100 110 120 130 140  
80  
90  
100 110 120 130 140  
LINE VOLTAGE (V  
)
LINE VOLTAGE (V )  
RMS  
RMS  
Power Factor vs. Line Voltage  
Original Circuit  
Output Power vs. Line Voltage  
Original Circuit  
1.000  
0.996  
0.992  
0.988  
0.984  
0.980  
15  
12  
9
8 LEDs  
6 LEDs  
6
4 LEDs  
3
80  
90 100 110 120 130 140  
LINE VOLTAGE (V  
80  
90  
100 110 120 130 140  
)
LINE VOLTAGE (V )  
RMS  
RMS  
www.national.com  
6
Output Power vs. Line Voltage  
Modified Circuits  
Power MOSFET Drain Voltage Waveform  
(VIN = 120VRMS, 6 LEDs, ILED = 350mA)  
15  
12  
9
Mod C  
Mod B  
6
Mod A  
30131196  
Original  
3
80  
90  
100 110 120 130 140  
LINE VOLTAGE (V  
)
RMS  
30131194  
Current Sense Waveform  
(VIN = 120VRMS, 6 LEDs, ILED = 350mA)  
FILTER Waveform  
(VIN = 120VRMS, 6 LEDs, ILED = 350mA)  
30131197  
30131198  
Note 1: Original Circuit: R14 = 1.50; Modification A: R14 = 1.21; Modification B: R14 = 1.00; Modification C: R14 = 0.75Ω  
7
www.national.com  
 
PCB Layout  
30131109  
Top Layer  
30131110  
Bottom Layer  
www.national.com  
8
Transformer Design  
Mfg: Wurth Electronics, Part #: 750311553 Rev. 01  
30131199  
30131114  
9
www.national.com  
The 120 Hz current ripple flowing through the LED string was  
measured to be 170 mApk-pk at full load. The magnitude of the  
ripple is a function of the value of energy storage capacitors  
connected across the output port. The ripple current can be  
reduced by increasing the value of energy storage capacitor  
or by increasing the LED string voltage.  
Experimental Results  
The LED driver is designed to accurately emulate an incan-  
descent light bulb and therefore behave as an emulated  
resistor. The resistor value is determined based on the LED  
string configuration and the desired output power. The circuit  
then operates in open-loop, with a fixed duty cycle based on  
a constant on-time and constant off-time that is set by select-  
ing appropriate circuit components.  
The LED driver switching frequency is measured to be close  
to the specified 79 kHz. The circuit operates with a constant  
duty cycle of 0.28 and consumes 9.25 W of input power. The  
driver steady state performance for an LED string consisting  
of 6 series LEDs is summarized in the following table.  
Performance  
In steady state, the LED string voltage is measured to be  
21.38 V and the average LED current is measured as 357 mA.  
Measured Efficiency and Line Regulation (6 LEDs)  
PIN(W) VOUT (V) ILED (mA) POUT (W)  
5.37 20.25 216 4.38  
VIN (VRMS  
90  
)
IIN (mARMS  
)
Efficiency (%) Power Factor  
60  
63  
66  
69  
72  
75  
77  
80  
82  
84  
81.6  
81.8  
81.9  
82.1  
82.3  
82.5  
82.7  
82.8  
82.9  
83.0  
0.9970  
0.9969  
0.9969  
0.9969  
0.9968  
0.9967  
0.9965  
0.9961  
0.9957  
0.9950  
95  
5.95  
6.57  
7.23  
7.89  
8.59  
9.25  
9.94  
10.62  
11.26  
20.47  
20.67  
20.86  
21.05  
21.23  
21.38  
21.53  
21.68  
21.80  
238  
260  
285  
309  
334  
357  
382  
406  
428  
4.87  
5.38  
5.94  
6.50  
7.09  
7.65  
8.23  
8.80  
9.34  
100  
105  
110  
115  
120  
125  
130  
135  
LED Current, Output Power versus Number of LEDs for Various Circuit Modifications ( VIN = 120 VAC  
)
# of LEDs  
Original Circuit (Note 2)  
Modification A (Note 2) Modification B (Note 2) Modification C (Note 2)  
ILED (mA)  
508  
POUT (W)  
7.57  
ILED (mA)  
624  
POUT (W)  
9.55  
ILED (mA)  
710  
POUT (W)  
11.05  
ILED (mA)  
835  
POUT (W)  
13.24  
4
6
8
357  
7.65  
440  
9.58  
500  
11.02  
590  
13.35  
277  
7.69  
337  
9.59  
382  
11.00  
445  
13.00  
Note 2: Original Circuit: R14 = 1.50; Modification A: R14 = 1.21; Modification B: R14 = 1.00; Modification C: R14 = 0.75Ω  
design also exhibits low current harmonics as a percentage  
of the fundamental current (as shown in the following figure)  
and therefore meets the requirements of the IEC 61000-3-2  
Class-3 standard.  
Power Factor Performance  
The LED driver is able to achieve close to unity power factor  
(P.F. ~ 0.99) which meets Energy Star requirements. This  
Current Harmonic Performance vs. EN/IEC61000-3-2 Class C Lim3i0t1s31195  
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10  
 
Electromagnetic Interference (EMI)  
The EMI input filter of this evaluation board is configured as  
shown in the following circuit diagram.  
30131167  
FIGURE 1. Input EMI Filter and Rectifier Circuit  
In order to get a quick estimate of the EMI filter performance,  
only the PEAK conductive EMI scan was measured and the  
data was compared to the Class B conducted EMI limits pub-  
lished in FCC – 47, section 15.  
30131177  
FIGURE 2. Peak Conductive EMI scan per CISPR-22, Class B Limits  
If an additional 33nF of input capacitance (i.e. C6) is utilized  
in the input filter, the EMI conductive performance is further  
improved as shown in the following figure.  
30131178  
FIGURE 3. Peak Conductive EMI scan with additional 33nF of input capacitance  
11  
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ILED = 350 mA  
Thermal Analysis  
The board temperature was measured using an IR camera  
(HIS-3000, Wahl) while running under the following condi-  
tions:  
# of LEDs = 6  
POUT = 7.3 W  
The results are shown in the following figures.  
VIN = 120 VRMS  
30131175  
FIGURE 4. Top Side Thermal Scan  
30131176  
FIGURE 5. Bottom Side Thermal Scan  
www.national.com  
12  
By using the line voltage injection technique, the FILTER pin  
has the voltage wave shape shown in Figure 7 on it. Voltage  
at VFILTER peak should be kept below 1.25V. At 1.25V current  
limit is tripped. C11 is small enough not to distort the AC signal  
but adds a little filtering.  
Circuit Analysis and Explanations  
Injecting line voltage into FILTER (achieving PFC > 0.99)  
If a small portion (750mV to 1.00V) of line voltage is injected  
at FILTER of the LM3444, the circuit is essentially turned into  
a constant power flyback as shown in Figure 6.  
Although the on-time is probably never truly constant, it can  
be observed in Figure 8 how (by adding the rectified voltage)  
the on-time is adjusted.  
30131118  
FIGURE 7. FILTER Waveform  
For this evaluation board, the following resistor values are  
used:  
R2 = R7 = 309kΩ  
R15 = 3.48kΩ  
Therefore the voltages observed on the FILTER pin will be as  
follows for listed input voltages:  
30131117  
FIGURE 6. Line Voltage Injection Circuit  
For VIN = 90VRMS, VFILTER = 0.71V  
For VIN = 120VRMS, VFILTER = 0.95V  
For VIN = 135VRMS, VFILTER = 1.07V  
The LM3444 works as a constant off-time controller normally,  
but by injecting the 1.0V rectified AC voltage into the FILTER  
pin, the on-time can be made to be constant. With a DCM  
Flyback, Δi needs to increase as the input voltage line in-  
creases. Therefore a constant on-time (since inductor L is  
constant) can be obtained.  
Using this technique, a power factor greater than 0.99 can be  
achieved without additional passive active power factor con-  
trol (PFC) circuitry.  
30131116  
FIGURE 8. Typical Operation of FILTER Pin  
13  
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Application Note 1656 Design Challenges of Switching LED Drivers  
Literature Number: SNVA253  
National Semiconductor  
Application Note 1656  
Chris Richardson  
Design Challenges of  
Switching LED Drivers  
October 2007  
Using a switching regulator as an LED driver requires the de-  
signer to convert a voltage regulator into a current regulator.  
Beyond the challenge of changing the feedback system to  
control current, the LEDs themselves present a load charac-  
teristic that is much different than the digital devices and other  
loads that require constant voltage. The LED WEBENCH®  
online design environment predicts and simulates the re-  
sponse of an LED to constant current while taking into ac-  
count several potential design parameters that are new to  
designers of traditional switching regulators.  
Once the VF of the LEDs has been determined from the V-I  
curve, the LED driver’s output voltage is calculated using the  
following formula:  
VO = n x VF + VSNS  
In this equation, 'n' is the number of LEDs connected in series,  
and 'VSNS' is the voltage drop across the current sense resis-  
tor.  
Designing for VO-MIN and VO-MAX  
In practice, the typical value of VF changes with forward cur-  
rent. Further analysis of total output voltage is needed be-  
cause VF also changes with process and with the LED die  
temperature. The more LEDs in series, the larger the potential  
difference between VO-MIN, VO-TYP and VO-MAX. An LED driver  
must therefore be able to vary output voltage over a wide  
range to maintain a constant current. IF is the controlled pa-  
rameter, but minimum and maximum output voltage must be  
predicted in order to select the proper regulator topology, IC,  
and passive components.  
Output Voltage Changes when LED  
Current Changes  
In the first step of the LED WEBENCH tool, "Choose Your  
LEDs", an LED is selected with a standard forward current,  
IF. This default value is provided by the LED manufacturers,  
and in most cases it represents the testing condition for that  
LED. Typical values for high-power LEDs are 350 mA, 700  
mA, and 1000 mA.  
30025102  
30025101  
FIGURE 2. VIN-MIN > VO-TYP, Buck Regulator Works  
FIGURE 1. V-I Curve with Typical VF and IF  
A typical example that can lead to trouble is driving three white  
(InGaN) LEDs from an input voltage of 12V ±5%. In Figure  
2, each LED operates at the typical VF of 3.5V, and the current  
sense adds 0.2V for a VO of 10.7V. Minimum input voltage is  
95% of 12V, or 11.4V, meaning that a buck regulator capable  
of high duty cycle could be used to drive the LEDs.  
Not all designs will use a standard current, however. The de-  
signer can select a different LED current, and then the forward  
voltage will change in the VLED box under step 2. The change  
in voltage comes from LEDs’ V-I curve. Figure 1 shows a  
curve from a 5W white (InGaN) LED that differs from the  
curves normally found in LED datasheets. LED manufactur-  
ers provide these curves, but they are often shown as I-V  
curves with voltage as the independent quantity. In Figure 1,  
forward current is the independent variable, reflecting the fact  
that in LED drivers current is controlled, and voltage is allowed  
to vary. The cross-hairs intersect at the standard/typical IF and  
VF values of 350 mA and 3.5V, respectively.  
However, a buck regulator designed for the typical VO will be  
unable to control IF if VO-MAX exceeds the minimum input volt-  
age. The same white LEDs with a typical VF of 3.5V have a  
VF-MAX of 4.0V. Headroom is tight under typical conditions,  
and the buck regulator will lose regulation with only a small  
increase in VF from one or more of the LEDs (Figure 3).  
WEBENCH® is a registered trademark of National Semiconductor Corporation.  
© 2007 National Semiconductor Corporation  
300251  
www.national.com  
 
 
To maintain safety and reliability in a parallel LED system,  
forward voltage should be binned or matched. Fault monitor-  
ing should detect LEDs that fail as either short or open circuits.  
Finally, the entire array should have evenly distributed heat  
sinking, to ensure that VF change with respect to die temper-  
ature occurs uniformly over all the LEDs.  
Selecting LED Ripple Current  
LED ripple current, ΔiF, in an LED driver is the equivalent of  
output voltage ripple, ΔvO, in a voltage regulator. In general,  
the requirements for ΔiF are not as tight as output voltage rip-  
ple. Where a ripple of a few milivolts to 4%P-P of VO is typical  
for ΔvO, ripple currents for LED drivers range from 10% to  
40%P-P of the average forward current, IF.Figure 5 and Figure  
6 show a typical ripple current of 25%P-P from a buck switching  
LED driver. A wider tolerance for ΔiF is acceptable because  
the ripple is too high in frequency for the human eye to see.  
General illumination applications (Such as lamps, flashlights,  
signs, etc.) can tolerate large ripple currents without harming  
the quality or character of the light. Allowing larger ripple cur-  
rent means lower inductance and capacitance for the output  
filter, which in turn translates to smaller PCB footprints and  
lower BOM costs. For this reason, ΔiF should generally be  
made as large as the application permits.  
30025103  
FIGURE 3. VIN-MIN < VO-MAX, Buck Regulator Fails to  
Regulate  
Pitfalls of Parallel LED Arrays  
Whenever LEDs are placed in parallel, the potential exists for  
a mismatch in the current that flows through the different  
branches. The forward voltage, VF, of each LED varies with  
process, so unless each LED is binned or selected to match  
VF, the LED or LED string with the lowest total forward voltage  
will draw the most current (Figure 4). This problem is com-  
pounded by the negative temperature coefficient of LEDs  
(and all PN junction diodes). The LEDs that draw the most  
current suffer the greatest increase in die temperature. As  
their die temperature increases, their VF decreases, creating  
a positive feedback loop. Elevated die temperature both re-  
duces the light output and decreases the lifetime of the LEDs.  
The true upper limit for ΔiF comes from the nonlinear propor-  
tion of heat to light that is generated as the peak current  
through the LED increases. Above approximately 40%P-P rip-  
ple, the LED can experience more heating during the peaks  
than cooling during the valleys, resulting in higher die tem-  
perature and reduction in LED lifetime.  
Some high-end applications require tighter control over LED  
ripple current. These include industrial inspection, machine  
vision, and blending of red, green, and blue for backlighting  
or video projection. The higher system cost of these applica-  
tions justifies larger, more expensive filtering to achieve ripple  
currents in the sub 10%P-P region.  
The system in Figure 4 also illustrates a potential over-current  
condition if one of the LEDs fails as an open circuit. Without  
some protection scheme, the entire drive current IO will flow  
through the remaining LED(s), likely causing thermal over-  
stress. Likewise, if one of the LEDs fails as a short circuit, the  
total forward voltage of that string will drop significantly, caus-  
ing higher current to flow through the affected branch.  
30025105  
FIGURE 5. LED Current (DC and AC)  
30025104  
FIGURE 4. Mismatched LEDs in Parallel  
www.national.com  
2
 
 
 
30025106  
FIGURE 6. Only LED Ripple Current  
30025107  
FIGURE 7. VF vs IF  
Dynamic Resistance  
Load resistance is an important parameter in power supply  
design, particularly for the control loop. In LED drivers it is also  
used to select the output capacitance needed to achieve the  
desired LED ripple current. In a standard power supply that  
regulates output voltage, the load resistance has a simple  
calculation:  
RO = VO / IO  
When the load is an LED or string of LEDs, however, the load  
resistance is replaced with the dynamic resistance, rD and the  
current sense resistor. LEDs are PN junction diodes, and their  
dynamic resistance shifts as their forward current changes.  
Dividing VF by IF leads to incorrect results that are 5 to 10  
times higher than the true rD value.  
Typical dynamic resistance at a specified forward current is  
provided by some manufacturers, but in most cases it must  
be calculated using I-V curves. (All LED manufacturers will  
provide at least one I-V curve.) To determine rD at a certain  
forward current, draw a line tangent to the I-V slope as shown  
in Figure 7. Extend the line to the edges of the plot and record  
the change in forward voltage and forward current. Dividing  
ΔVF by ΔIF provides the rD value at that point. Figure 8 shows  
a plot of several rD values plotted against forward current to  
demonstrate how much rD shifts as the forward current  
changes.  
30025108  
FIGURE 8. rD vs IF  
Dynamic resistances combine in series and parallel like linear  
resistors, hence for a string of 'n' series-connected LEDs the  
total dynamic resistance would be:  
One amp is a typical driving current for 3W LEDs, and the  
calculation below shows how the dynamic resistance of a 3W  
white InGaN was determined at 1A:  
rD-TOTAL = n x rD + RSNS  
A curve-tracer capable of the 1A+ currents used by high pow-  
er LEDs can be used to draw the I-V characteristic of an LED.  
If the curve tracer is capable of high current and high voltage,  
it can also be used to draw the complete I-V curve of the entire  
LED array. Total rD can determined using the tangent-line  
method from that plot. In the absence of a high-power curve  
tracer, a laboratory bench-top power supply can be substitut-  
ed by driving the LED or LED array at several forward currents  
and measuring the resulting forward voltages. A plot is cre-  
ated from the measured points, and again the tangent line  
method is used to find rD.  
ΔVF = 3.85V – 3.48V  
ΔIF = 1.5A – 0A  
rD = ΔVF / ΔIF = 0.37 / 1.5 = 0.25Ω  
3
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Notes  
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OR COMPLETENESS OF THE CONTENTS OF THIS PUBLICATION AND RESERVES THE RIGHT TO MAKE CHANGES TO  
SPECIFICATIONS AND PRODUCT DESCRIPTIONS AT ANY TIME WITHOUT NOTICE. NO LICENSE, WHETHER EXPRESS,  
IMPLIED, ARISING BY ESTOPPEL OR OTHERWISE, TO ANY INTELLECTUAL PROPERTY RIGHTS IS GRANTED BY THIS  
DOCUMENT.  
TESTING AND OTHER QUALITY CONTROLS ARE USED TO THE EXTENT NATIONAL DEEMS NECESSARY TO SUPPORT  
NATIONAL’S PRODUCT WARRANTY. EXCEPT WHERE MANDATED BY GOVERNMENT REQUIREMENTS, TESTING OF ALL  
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Copyright © 2011, Texas Instruments Incorporated  
National Semiconductor  
2900 Semiconductor Dr.  
Santa Clara, CA 95052  
M Reynolds, David Zhang  
Applications Engineer  
SSL Division - Longmont,  
CO 80501  
LM3444 MR16 Boost Reference Design for  
Non-Dimming & Dimming LED Applications  
March 31, 2011  
Revision 1.0a  
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  
Channel - 1 (yellow trace) = Input line voltage  
Channel - 3 (purple trace) = Input line current  
Channel - 4 (green trace) = bulb current  
Improper SSL MR16 operating waveform  
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  
12V, 50W Halogen  
MR16 Bulb  
IBULB  
IIN  
LINE  
LINE  
+12V  
120VAC  
Power  
Supply  
Transformer  
VIN  
(Electronic)  
NEUTRAL  
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  
CAP, ELECT, 220uF, 35V, +/-20%, Radial 8x11.5mm  
CAP, CERM, 22uF, 25V, +/-10%, X5R, 1210  
CAP, CERM, 330pF, 100V, +/-5%, X7R, 0603  
CAP, CERM, 4.7uF, 50V, +/-10%, X7R, 1210  
CAP, CERM, 4.7uF, 25V, +/-10%, X5R, 0805  
Diode, Schottky, 30V, 3A, SMA  
MuRata  
Panasonic  
MuRata  
AVX  
GRM216R61E105KA12D  
ECA-1VHG221  
C2  
C3  
GRM32ER61E226KE15L  
06031C331JAT2A  
GRM32ER71H475KA882  
GRM21BR61E475KA12L  
B330A-13-F  
C4  
C5  
MuRata  
MuRata  
C6  
D1-D4  
D5  
D6  
D7  
D8  
L1  
Diodes Inc.  
Diode, Schottky, 60V, 1A, SMA  
Diodes Inc.  
B160-13-F  
TVS BI-DIR 24V 400W SMA (Optional)  
Diode, Zener, 11V, 500mW, SOD-123  
Diode, Zener, 33V, 500mW, SOD-123  
Ind, Shielded Drum Core, Ferrite, 33uH, 1.1A, 0.31 ohm, SMD  
Transistor, NPN, 80V, 500mA, SOT-23  
MOSFET, N-CH, 60V, 1.2A, SOT-23  
Diodes Inc  
SMAJ24CA-13-F  
CMHZ4698  
Central Semiconductor  
Central Semiconductor  
CMHZ4714  
MSS6132-333MLB  
Coilcraft  
Central Semiconductor  
Q1  
Q2  
R1  
CMPTA06  
Diodes Inc.  
ZXMN6A07FTA  
ERJ-6RSJR10V  
RES, 0.1 ohm, 5%, 0.125W, 0805  
Panasonic  
R2, R4  
R3  
RES, 1.00k ohm, 1%, 0.1W, 0603  
RES, 12.4k ohm, 1%, 0.1W, 0603  
RES, 1.00 ohm, 1%, 0.5W, 1206  
RES, 4.7 ohm, 5%, 0.125W, 0805  
Vishay-Dale  
Vishay-Dale  
Stackpole Electronics Inc  
Yageo  
CRCW06031K00FKEA  
CRCW060312k4FKEA  
CSR1206FK1R00  
R5  
RC0805JR-074R7L  
R6  
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  
I3  
I2  
LINE  
Vp  
Vp  
Vs  
VIN  
LED+  
LED  
Board  
120VAC  
Power  
Supply  
LM3444 MR16  
LED Driver  
Transformer  
V3  
V1  
V2  
(Electronic)  
Vs  
LED-  
NEUTRAL  
VIN  
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  
I4  
I1  
I3  
I2  
LINE  
Vp  
Vs  
VIN  
LED+  
LED  
120VAC  
Power  
Supply  
Board  
Triac  
Dimmer  
Transformer  
LM3444 MR16  
LED Driver  
V4  
V1  
V3  
V2  
( Electronic )  
NEUTRAL  
Vs  
LED-  
VIN  
Vp  
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  
Specs  
VIN  
Units  
11.91  
0.708  
7.97  
VAC  
IIN  
A
W
VDC  
A
PIN  
(1)  
VOUT  
23.55  
0.281  
6.62  
(1)  
ILED  
(2)  
POUT  
W
-
Efficiency  
83.0%  
0.948  
Power Factor  
-
Performance with transformer  
LET-75  
LM3444 BOOST 7 LEDs  
Specs  
VIN  
Units  
120  
0.07  
VAC  
IIN  
A
W
VDC  
A
8.18  
PIN  
(1)  
23.5  
VOUT  
(1)  
0.270  
6.23  
ILED  
(2)  
POUT  
W
-
Efficiency  
77.6%  
0.970  
Power Factor  
-
HATCH RS12-80M  
LM3444 BOOST 7 LEDs  
Specs  
VIN  
Units  
120  
0.072  
8.13  
VAC  
IIN  
A
W
VDC  
A
PIN  
23.5  
VOUT  
0.270  
6.23  
ILED  
POUT  
W
-
Efficiency  
Power Factor  
78.0%  
0.934  
-
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  
Specs  
VIN  
Units  
11.91  
0.682  
7.66  
VAC  
IIN  
A
W
VDC  
A
PIN  
(1)  
VOUT  
26.64  
0.238  
6.34  
(1)  
ILED  
(2)  
POUT  
W
-
Efficiency  
82.8%  
0.946  
Power Factor  
-
Performance with transformer  
LET-75  
LM3444 BOOST 8 LEDs  
Specs  
VIN  
Units  
120  
0.067  
7.86  
VAC  
IIN  
A
W
VDC  
A
PIN  
26.5  
VOUT  
0.230  
6.10  
ILED  
POUT  
W
-
Efficiency  
Power Factor  
77.5%  
0.970  
-
HATCH RS12-80M  
LM3444 BOOST 8 LEDs  
Specs  
VIN  
Units  
120  
0.069  
7.82  
VAC  
IIN  
A
W
VDC  
A
PIN  
26.5  
VOUT  
0.230  
6.10  
ILED  
POUT  
W
-
Efficiency  
Power Factor  
77.9%  
0.930  
-
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  
Specs  
VIN  
Units  
11.92  
0.668  
7.51  
VAC  
IIN  
A
W
VDC  
A
PIN  
(1)  
VOUT  
28.25  
0.220  
6.22  
(1)  
ILED  
(2)  
POUT  
W
-
Efficiency  
82.8%  
0.946  
Power Factor  
-
Performance with transformer  
LET-75  
LM3444 BOOST 9 LEDs  
Specs  
VIN  
Units  
120  
0.066  
7.74  
VAC  
IIN  
A
W
VDC  
A
PIN  
28.0  
VOUT  
0.215  
6.02  
ILED  
POUT  
W
-
Efficiency  
Power Factor  
77.8%  
0.970  
-
HATCH RS12-80M  
LM3444 BOOST 9 LEDs  
Specs  
VIN  
Units  
120  
0.068  
7.64  
VAC  
IIN  
A
W
VDC  
A
PIN  
28.0  
VOUT  
0.212  
5.94  
ILED  
POUT  
W
-
Efficiency  
Power Factor  
77.7%  
0.930  
-
LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR  
Page 19 of 20  
Revision History  
Date  
Author  
Revision  
Description  
LM3444-MR16-Boost Reference Design NATIONAL SEMICONDUCTOR  
Page 20 of 20  
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