TND373/D

Rev. 0, Oct -- 2009

1 W to 5 W LED Driver for MR16 LED

Reference Design Documentation Package

 Disclaimer: ON Semiconductor is providing this reference design documentation package “AS IS” and the recipient
assumes all risk associated with the use and/or commercialization of this design package. No licenses to ON Semiconductor’s
or any third party’s Intellectual Property is conveyed by the transfer of this documentation. This reference design
documentation package is provided only to assist the customers in evaluation and feasibility assessment of the reference design.
It is expected that users may make further refinements to meet specific performance goals.

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TND373/D

1 W to 5 W LED Driver for

MR16 LED

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Introduction TECHNICAL NOTE

The market for High--Brightness LED’s (HB--LED) boost topologies. Once understood, the buck--boost
continues to rise rapidly. Over the last few years LED topology can offer many advantages for cost effective HB
efficacy (lm/W) has more than doubled while flux per LED lighting when Vin overlaps Vf.
package continues to rise rapidly making them more useful
for many new applications. We have seen revolutionary new Overview
products in handheld flashlights, architectural lighting and This reference document describes a built and tested,
street lighting. The challenge continues to be making a more GreenPoint® solution for a 1 to 5 W LED driver for MR16
cost effective system versus incandescent and compact LED replacement. The circuit is proposed for driving
fluorescent bulbs. HB--LED (high--brightness LED) in a variety of lighting
In many applications this challenge involves powering the applications but is configured in size and features for an
HB--LED’s from a wide input--voltage range source. This is MR16 LED replacement. Configurations like this are found
especially true in general illumination applications like in 12 Vac / 12 Vdc track lighting applications, automotive
track lighting where the power source is a 12 Vac or +12 Vdc applications, and low voltage AC landscaping applications
source that can be very loosely regulated. The LED’s need as well as task lighting such as under--cabinet lights and desk
to be driven by a current source rather than a voltage source lamps that might be powered from standard off--the--shelf
since the forward voltage (3.4 V nominal) can vary more Vac wall adapters.
than ±20% over process tolerance and temperature. The circuit is based around the ON Semiconductor
Moreover given the flux of current 1 W warm white power NCP3065 operating at ~150 kHz in a non--isolated
LEDs, it is common to need 3--4 LEDs to replace the light configuration. A key consideration in this design was
output of a 20 W incandescent. To obtain predictable and achieving flat current regulation across input line variation
matched luminosity and chromaticity it is also desirable to and output voltage variation with a 12 Vac input. It also
drive the LED’s with a constant current. The buck--boost features an auto--detect circuit in combination with the
topology meets this requirement from an architectural NCP3065 which allows input from a 12 Vdc or 12 Vac
perspective but it not as common as the standard buck or supply and still maintain targeted output current regulation.

12 VACIN

NCP3065

Compensation
Network

Figure 1. Simplified Block Diagram

Actual Size

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Basic Power Topology energy in L. In this stage, the capacitor C supplies energy to
The principle of the Buck--Boost converter is fairly simple the output load;
(see Figure 2): While in the Off--state, the inductor is connected to the
While in the On--state, the input voltage source is directly output load and capacitor through the Output Diode, so
connected to the inductor (L). This results in accumulating energy is transferred to the load.

ID
Vin
IQ
Vsw
Vout

Vgate
IL C
RLoad

Ton
From Inductor Volt Second V = L di
Balance and: dt
Vgate
Toff

Vin
Vi(Ton) Vo(Toff)
=
Vsw L L
Vo--Vf

IQ VinD = Vo(1 − D)

ID
Vo D
=
Vin (1 − D)

IL

Figure 2. Buck--Boost Operation

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Figure 3. Vswitch Node Waveform

TSD
NC
Set Switch
dominant Collector

R Q
ILimit
Comp
S
Ipk
Sense S Q Switch
Set Emitter
R dominant
0.2V
Oscillator
Ct
Vcc Ct

Vref GND
Comp
Inv

Figure 4. NCP3065 Burst Mode Controller

Burst Mode Control R8 is used to sense the inductor current and is fed to the
The basic control loop consists of a 235 mV internal FB pin of the NCP3065.
Reference, a Feedback Comparator, and two Set--Dominant This application produces OFF time instantaneous
RS Latches. Basically the NCP3065 allows the Power FET (Ivalley) inductor current control (see Figure 5). A cycle of
for the Buck--Boost stage to switch ON as the Feedback switch ON time is only allowed to start once the OFF time
Voltage falls below the reference voltage. The Power FET Inductor current crosses the Vref threshold.
will be then be forced OFF unconditionally during Ct Ramp
down.

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Ipeak
Ivalley

Ton Toff Ton Toff

Average Load Current = Area During Toff

Figure 5. Buck--Boost Inductor Current

Since the controller does not provide integral PWM 0.4

control and utilizes only a comparator trip point for
feedback, the peak to average load current is not in direct
proportion as in a Buck Converter, but rather follows the 0.3
following formula:
Iave, (Vin)

Vo
⎧ ⎧V 1 − ⎫⎫
⎪⎪1 − V  0.2
1 o V o+V Vo
=⎪I ⎪L in
I ave valley +
2 F
⎩ ⎩ ⎭⎭ o + V in

0.1
Where, Ivalley is the lowest inductor current point. Plotting
Iave vs Vin shows a dramatic curve which would cause a
significant change in light output of the LED (see Figure 6).
0
6 8 10 12 14 16 18
1.4 Vin, N
Figure 7. Average LED Current vs Vin DC
(With Vin Compensation)
1.2

A resistive divider network consisting of R3, R5 and

Iave, (Vin)

1 summing resistor R4 are used to add Vin proportional

voltage to the FB pin in order to reduce the load current as
0.8 Vin is increased. This has the effect of flattening the curve of
Figure 6 and reduces the overall current error (see Figure 7).
This average line can be DC shifted with R8 and the ends can
0.6 be aligned by adjusting R5, R3 and R4.
R9 and C6 are used to limit the gate to source voltage on
0.4 the external switch at high input voltage. The resistor divider
0 5 10 15 20
network of R9 and R2 are used to program and gate to source
Vin, N
maximum.
Figure 6. Average LED Current vs Vin DC
(Without Vin Compensation)
V gs = V in −  V in ⋅ R9
R9 + R2
 (eq. 1)

Therefore an input voltage feed--forward compensation

network is used to reduce the error due to the nonlinear
response of the Iout vs Vin curve.

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Pulsed Feedback Resistor R7 and D5 add current to the Ct timing capacitor C2. This
R7 and D5 are used to reduce the possibility of pulse effectively limits the maximum achievable duty cycle of the
skipping (see Figure 8). Since burst mode control involves NCP3065. When conditions warrant low duty cycle, R7 and
only one feedback voltage, cross--detection per cycle and D5 make higher than desired duty cycles unavailable. D7 is
does not involve the use of a window comparator, it is necessary to block voltage during the OFF time, since this
possible to have skipped pulses which do not effect the DC is Buck--Boost Topology. More information on Pulsed
regulation but could be visible as flicker in an LED Feedback compensation is available in the NCP3065 data
application if the pulsing had a low frequency component. sheet.

Figure 8. Pulsed Feedback Resistor

AC Operation vs DC for some finite portion ~80% of the 120 Hz line cycle, and
Since there is a half sine wave input to the Buck--Boost then no output for ~20%. This has the effect of reducing the
stage, there is a different operating point as compared with average current by ~20% when operating with AC input.
pure DC input. Since small size is a goal for this design very Thermal consideration should be taken when running with
little input capacitance is used past the full bridge rectifier. > 12 Vac. In most applications the module is potted to
As a result the line voltage can drop to as little as 3 V increase thermal dissipation.
depending on the input capacitance selection. Therefore, the An additional AC compensation network is added to the
input to the converter is a full wave rectified sine wave. Vin Compensation to account for the different operating
Since the regulator is non--functional below ~4 V there are point (see Figure 9).
dead spots in the regulation. So we end up with regulation

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Figure 9. Pulsed Feedback Resistor

Protection the power FET with reasonable voltage margin. This may
Z1 and R1, along with the Current limit function of the require some trial and error to select since the clamp voltage
NCP3065, are used for open circuit protection. In the event will stretch depending on how much energy needs to be
of an open circuit at the load, the loop will try to increase the absorbed.
output voltage in order to satisfy the current demand which
feeds back zero current. When (Vin + Vout) exceeds the Increasing Output Current
voltage of Z1, current will flow in R1 which triggers the The reference design is configured for 350 mA average
current limit function of the NCP3065. LED current. Increasing the current regulation point on the
Short circuit protection is handled with a fuse, F1, on the reference board is as simple as cutting the current sense
input. Surge protection from inductive loads is an important resistor R8 in half from 250 mΩ to 125 mΩ. Also, the input
consideration specifically in transformer fed systems that fuse must be increased to accommodate the increased input
carry significant source inductance such as found with current draw. Heat sinking may be required depending on
magnetic transformers used in landscape lighting the implementation of the housing and the environmental
applications. The surge device needs to be selected to a characteristics when moving to the higher power design.
voltage that will never exceed the gate to source voltage of

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PC BOARD

Figure 10. Component Placement (Top)

Figure 11. Traces (Top View)

Figure 12. Component Placement (Bottom)

Figure 13. Traces (Bottom View)

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Figure 14. Reference Design

0.457” x 1.148” (11 mm x 29 mm)

Remember this is an inverting output. So the negative need to be floating (ground connection removed from the
output will connect to the anode of the LED, and the positive AC wall source) or there will be a ground loop / short circuit
output will connect to the cathode of the LED. that will cause the device to turn off.
Also note, when trying to make measurements with a
scope probe, that ground is NOT ground. The scope will

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SCHEMATIC

Figure 15.

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Table 1. BILL OF MATERIALS

Qty Ref Value Part Number Description Manufacturer
1 F1 4A 0457004.NR Fuse LittleFuse
1 C3 10 mF GRM31MF51A106ZA01L Ceramic Chip Capacitor Murata
1 C6 1 nF GRM188R71H102KA01D Ceramic Chip Capacitor Murata
1 C1 1 mF GRM188R61E105KA12D Ceramic Chip Capacitor Murata
1 C2 5.6 nF GRM188R71H562KA01D Ceramic Chip Capacitor Murata
1 C4 10 mF GRM32NF51E106ZA01L Ceramic Chip Capacitor Murata
1 C5 10 mF GRM32NF51E106ZA01L Ceramic Chip Capacitor Murata
1 D1 1 A, 30 V MBR130T1G DIODE, SCHOTTKY ON Semiconductor
1 D2 1 A, 30 V MBR130T1G DIODE, SCHOTTKY ON Semiconductor
1 D3 1 A, 30 V MBR130T1G DIODE, SCHOTTKY ON Semiconductor
1 D4 1 A, 30 V MBR130T1G DIODE, SCHOTTKY ON Semiconductor
1 D6 2 A, 60 V MBRS260T3 DIODE, SCHOTTKY ON Semiconductor
1 Q1 PNP MBT3946DW1T1 General Purpose NPN Transistor ON Semiconductor
1 D5 0.2 A, MMSD4148T1 Diode, Small Signal ON Semiconductor
100 V

1 D8 0.2 A, MMSD4148T1 Diode, Small Signal ON Semiconductor

100 V

1 Z1 36 V MM5Z36VT1 DIODE, ZENER ON Semiconductor

1 L1 68 mH MSS1278-683MLD INDUCTOR, SM Coilcraft
1 U1 40 V 1.5 A NCP3065DR2G Switching Regulator ON Semiconductor
1 M1 P--FET NTGS4111PT1G MOSFET, P ON Semiconductor
1 R4 1.2k CRCW04021K20FKED Resistor Vishay / Dale
1 R1 100 CRCW0402100RFKED Resistor Vishay / Dale
1 R3 162k CRCW0402162KFKED Resistor Vishay / Dale
1 R6 196 CRCW0402196RFKED Resistor Vishay / Dale
1 R7 22k CRCW040222K0FKED Resistor Vishay / Dale
1 R5 22k CRCW040222K0FKED Resistor Vishay / Dale
1 R2 1k CRCW04021K00FKED Resistor Vishay / Dale
1 R9 200 CRCW0402200RFKED Resistor Vishay / Dale
1 R8 0.25 CSR1/20.25FICT-ND Resistor Vishay / Dale
1 D7 P6SMB22CAT3 ZENER, BACK TO BACK ON Semiconductor

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MEASUREMENTS
(12 Vac Data)

0.4 0.8

0.75
0.38

0.7
0.36
0.65
0.34
0.6

0.32
0.55
Iout Efficiency
0.3 0.5
8 9 10 11 12 13 14 15 7 9 11 13 15 17 19

Figure 16. Iout vs Vac Figure 17. Efficiency vs Vdc

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