Académique Documents
Professionnel Documents
Culture Documents
Design Guide
LED
Light-Emitting
Diode (LED)
Design Guide
Table of Contents
Page
Introduction
3-4
5-7
8-10
11
12-15
16-17
18-19
20-21
22
23
24-25
26-28
29-33
Conclusions
34
References
34
Legal Disclaimers
35
N. America
East Asia
20%
5% S. America
40%
22%
EU
50
30%
LED Lighting
Share of overall lighting market
40
25%
20%
30
15%
20
10%
10
0
5%
2009
2010
2011
2012
2013
2014
0%
In the commercial sectors, the business case is not only justified from double digit
energy savings but also large maintenance and labor cost reductions. Utility rebates and
government financial incentives for energy efficiency further help reduce the initial cost
of LED lamp and luminaire installations. As most LED lamps are specified to last around
50,000 hours versus 1000 hours for incandescent and 8,000 hours for CFLs, fewer
maintenance staff hours are required to replace lamps in large facilities. Further, reduction
in CO2 emissions by going to LED alternatives is also a key driving factor near and dear to
government environmental agencies. A single 100W incandescent bulb for example, that
is on four hours a day produces 139 pounds of carbon per year. Switching to a 12 watt LED
lamp which has the equivalent light output of a 75W incandescent will emit only 7.33 lbs.
of carbon per year.
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Over the next couple of years, LED lighting adoption will be highest in retail accent lighting
and cold storage followed by street, highway, parking lot and public structure illumination,
and niche applications in commercial building lighting. Street lighting energy efficiency
measures have been initiated by many local cities and municipalities around the world
seeking to replace high pressure sodium (HPS) lamps with LED lights. For parking lots and
parking garages, HPS, metal halides and fluorescents are the main targets for replacement.
The United States is leading the way for establishing uniform performance and safety
standards for certain indoor commercial lighting as well as roadway, parking lot and garage
illumination. The EPAs Energy Star specifications apply to LED replacement bulbs for
residential and certain commercial applications. The US Dept of Energys Municipal Solid
State Street Lighting Consortiums LED Roadway model spec, and the Commercial
Building Energy Alliance Parking Lot and Structure Outdoor LED lighting performance spec
are examples of important documents released in late 2011 and early 2012 respectively.
A Littelfuse video, Circuit Protection and Reliability Solutions for the LED Lighting
Market, provides an overview of global standards for circuit protection of LED lighting.
Littelfuse describes
the market and
circuit protection
needed for LED
lighting.
To view the video,
visit: https://vimeo.com/50692101
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LED Driver
Heat Sink
Parabolic Reflector
Packaged LED
Lens
Figure 2. Typical residential LED lamp construction.
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AC Line Fuse
MOV
SPD
AC Input
EMI Filter
High Voltage
DC Fuse
Line Rectifier
TVS Diode
PTC
PLED
A positive temperature
coefficient resistor can help
protect LEDs from over-current
and over-temperature.
Open circuit
LED protection
device
LEDs
DC-DC Converter
L
Osc.
N
G
Iso /
Step
Down
Constant
Current LED
String Driver
TVS Diode
Transient protection
for energy let through
to the LED circuit
MOV
Surge protection device with
high surge withstand MOVs
(e.g., 25 - 34mm dia. Sizes)
Controller /
Opto Couplers
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1.0 1.0
1.0 1.0
FrontFront
TimeTime
= 8 s
= 8 s
0.6 0.6
0.6 0.6
0.4 0.4
Duration
Duration
= 50 =s50 s
0.2 0.2
0
I(t)/Ip
0.8 0.8
I(t)/Ip
0.8 0.8
V(t)/Vp
V(t)/Vp
FrontFront
TimeTime
= 1.2=s
1.2 s
Duration
= 20s
Duration
= 20s
0.4 0.4
0.2 0.2
20
20
40
40
60
60
Time
Time
(s) (s)
80
80
100 100
Combination
Combination
WaveWave
open-circuit
open-circuit
voltage
voltage
10
10
20
20
30
30
Time
Time
(s) (s)
40
40
50
Combination
Combination
WaveWave
short-circuit
short-circuit
current
current
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For self-ballasted lamps and luminaires < 25W, 500V/250A: Apply 500V L-L with 2 ohm
source impedance and 1kV L-G with 12 ohms impedance.
For luminaire > 25W, 1000V/500A: Apply 1kV L-L with 2 ohm source impedance and
2kVL-G with 12 ohms impedance.
0.8
10 s
0.6
V(t)/Vp
0.4
0.2
0
-0.2
-0.4
-0.6
-0.8
-1.0
10
20
30
Time (s)
The 100 kHz Ring Wave (voltage and current)
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Fuse Options
MOV Options
TVS Diode
V150LA2P
V175LA2P
V240ZA05P
V240CH8
P6KE300CA
SMAJ400A
SMAJ440A
SMBJ400A
SMBJ440A
1.5KE400A
1.5KE440CA
ENERGY STAR Program Requirements for Integral LED Lamps (for USA)
IEC 61547 Equipment for general lighting purposes - EMC immunity requirements (for Europe/ Asia / Australia)
1. IEC 61000-4-5 Surge Immunity Test. For lamps < 25W:
1.250s/820s combination wave 500V/250A line-to-line test (10
strikes, 5+ at phase angles 90, 5 at phase angle 270)
V300LA2P
V320LA7P
V430CH8
P6KE300CA
SMAJ400A
SMAJ440A
SMBJ400A
SMBJ440A
1.5KE400A
1.5KE440CA
V300LA10P
V320LA10P
V300SM7
V320SM7
P6KE300CA
SMAJ400A
SMAJ440A
SMBJ400A
SMBJ440A
1.5KE400A
1.5KE440CA
NOTE: MOVs were tested with 1.250s open circuit voltage waveform and 820s short circuit current waveform forming a combo waveform with 2 ohm
source impedance. Standard method was used for testing the MOVs per datasheet specifications which consisted of driving relevant surge current through the
part with the generated combination wave. In real world events, actual peak current through the lamp with typical circuit impedance path will likely be lower.
Littelfuse has tested the above part selections to a more stringent level as it complies with our internal testing standards.
Table 1. A sampling of Littelfuse devices designed for LED lamp surge protection.
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United States
Europe
S. America
Japan
Surge Immunity (Combo wave) Energy Star (Based IEC/EN 61547 IEC/
1.250s Voc/ 820s Isc
on IEEE C62.41.2)
EN 61000-4-5
Ring wave 2.5kV
500V/250A
Integrated LED light bulbs
1kV/500A
(E27 Base Europe / E26 Base USA) 100kHz Class A
(LED retrofit lamps and indoor
commercial)
Taiwan
China
Korea
JIS C 61000-4-5
(Based on IEC/EN
61000-4-5)
500V/250A
1kV/500A
CNS 14676-5
GB/T 18595 (Based K61547 (Based on
(Based on IEC/EN on IEC/EN 61547)
IEC/EN 61547)
61000-4-5)
500V/250A
500V/250A
500V/250A
1kV/500A
1kV/500A
1kV/500A
JIS C 61000-4-5
(Based on IEC/EN
61000-4-5)
4kV/2kA
CNS 14676-5
(Based on IEC/EN
61000-4-5)
4kV/2kA
DOE (Based on
IEEE C.62.41.2)
Category C-Low
6kV/3kA
Category C-High
20kV/10kA
ANSI/NEMA
(spec. no. TBD)
Safety
UL 8750, UL 1310,
UL 1993, UL 1598
CNS standards
GB/T 17626.5
KS C IEC61000-4-5
(Based on IEC/EN (Based on IEC/EN
61000-4-5)
61000-4-5)
4kV/2kA
4kV/2kA
GB24819-2009/
IEC62031 LED
Module for general
lighting-safety
KS standards
Safety refers to overcurrent protection, particularly short circuit and overload protection. In
North America, UL8750 is the Standard for Safety of LED Equipment, which pertains to
residential LED lamps and outdoor luminaire assemblies. The purpose of this requirement is
to minimize the risk of shock and fire. It calls out the use of an overcurrent protection device
to interrupt or limit the current during a short circuit or overload condition. Fuses are the most
widely used and reliable protection technology to protect against such conditions. Outside
the US, the IEC/EN 61347 LED driver (power supply) specification and IEC/EN 62031 for LED
arrays/modules contain safety requirements for these power supplies.
In Europe and other countries outside the United States, the surge immunity requirements
are referenced in documents such as IEC/EN 61547 that references IEC/EN 61000-4-5,
which delineates different surge testing levels based on 8x20s short circuit current
combination waveform. For outdoor lighting applications, these levels can range from
4kV/2kA in many Asian countries up to 10kV/5kA in Europe.
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Location Category
Waveform
Pk Voltage (kV)
Pk Current (kA)
Source
Application
1.2/50s
8/20s
Impedance (Ohms)
A (Indoors)
0.5
12
C Low
C High (Outdoors)*
20
10
Location Category
Pk Voltage (kV)
Pk Current (kA)
Waveform
Source
Impedance (Ohms)
A (Indoors)
0.2
30
0.5
12
C Low or High
0.5
12
*A combination waveform where specified peak current is calibrated on the tester by shorting the output together prior to
connection to the luminaire. Single phase modes: L-N L-G N-G. Polyphase Modes: L-L L-N Ls-G
Table 3. IEEE C.62.41-2002 test requirements for LED luminaires.
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Coupling Modes
L1 toPE, L2 to PE, L1 to 72
Test Strikes
1 minute
*This is a MINIMUM requirement. Note that for most combination wave generators, which have a
source impedance of 2W, the generator charging voltage will need to be raised above the specified
level (to somewhere in the vicinity of 20kV) to obtain the specified current peak.
Table 4. DOE MSSSLC 1.2/50s Combination Wave Test Specification
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0.5kA
6kV
Coupling Modes
L1 to PE, L2 to PE, L1 to L2
Test Strikes
1 minute
Table 5. DOE MSSSLC 0.5s Rise Time 100kHz Ring Wave Test Specification
The DOE requirements are similar to those in IEEE C.62.41-2002, IEEEs Recommended
Practice on Characterization of Surge in Low Voltage (1000V or less) in AC Power Circuits,
with a couple of small differences. DOEs MSSSLC calls out a combination wave and
not separate and successive application of the 10kV/10kA surge levels as stated in
IEEE C.62.41-2002.
The DOE MSSSLC waveform is a combination 1.2/50s open circuit voltage and 8/20s
short circuit current waveform (Table 4). To perform this test the specified peak current is
calibrated on the tester by shorting the output to ground prior to connection to the luminaire.
The actual current that gets driven through the luminaire is a result of the combination wave
and will likely be lower based on the effective impedance of the luminaire. In turn, the actual
current that would run through the MOVs (at the AC input of Figure 3, or elsewhere) will
probably be less than the total current that enters the luminaire, based on available current
paths and their effective impedances. This test setup is depicted in Figure 8.
Test in LF
A1
10kA
A2
A3
Powering
Circuitry
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Fuse Options
MOV Options
TVS Diode
(DC)
PLED6S
(ILED=1A MAX;
P6KE300CA
SMAJ400A
SMAJ440A
SMBJ400A
SMBJ440A
1.5KE400A
1.5KE440CA
DO-214AA Pkg)
PLED6Q12
(ILED=1A MAX;
33mm QFN Pkg)
PLED5Q12
(ILED=0.5A MAX;
22mm QFN Pkg)
PLED5HT
(ILED=0.7A MAX;
SOT-89 Pkg)
Fuse Options
MOV Options
TVS Diode
(DC)
P6KE300CA
SMAJ400A
SMAJ440A
SMBJ400A
SMBJ440A
1.5KE400A
1.5KE440CA
PLED6S
(ILED=1A MAX;
DO-214AA Pkg)
PLED6Q12
(ILED=1A MAX;
33mm QFN Pkg)
PLED5Q12
(ILED=0.5A MAX;
22mm QFN Pkg)
NOTE: MOVs were tested with 1.250s open circuit voltage waveform and 820s short circuit current waveform forming a combo waveform with 2 ohm source impedance.
Standard method was used for testing the MOVs per datasheet specifications which consisted of driving 10kA through the part with the generated combination wave. Peak voltage
was adjusted to a bit higher than 20kV in order to drive exactly 10kA of peak current. In real world events, actual peak current through the luminaire with typical circuit impedance
path will lik ely be lower. Littelfuse has tested the above part selections to a more stringent level as it complies with our internal testing standards. The TVS diodes and PLED options
were not tested due to the custom nature of each commercial lighting design. The parts highlighted in green are design-registrable.
Table 6. LED lighting circuit protection for compliance with IEC 61000-4-5 and IEEE C.62.41-2002.
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TMOV
Varistor
MOV Disk
TMOV
Neutral
TMOV
Ground
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Fuse
TMOV20R130M
Neutral
D1
LED
Normally
On
R1
47k,0.5W
Figure 10. Indicator circuit using the Littelfuse iTMOV varistor (LED normally on).
In Figure 10, an iTMOV varistor is used to protect the L-N connection of a typical U.S.
120Vac line. An AC rated LED is placed across the iTMOV varistors indicator lead and the
Neutral line. See the TMOV and iTMOV Varistor Series datasheet for more detail on these
Littelfuse products.
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1-4kV. The varistor (MOV2 in Figure 11) is usually located after the fuse on the AC mains,
and can range from 7-14mm in diameter. However, to provide higher level surge immunity,
outdoor lighting OEMs may want to add surge protection devices (SPDs) on the AC input
lines of their luminaires ahead of the LED driver. Typically, compliance testing of luminaires
involves 20kV/10kA surges in North America and up to 10kV/5kA1 in Europe.
MOV2
MOV1
MOV2
AC Input
SPD
LED DRIVER
MOV1
AC Input
LED DRIVER
UltraMOV 25S
or TMOV25S
Series
SPD
UltraMOV 25S
or TMOV25S
Series
Figure 11. SPD protection schemes that increase the surge immunity of an LED driver.
SPD modules are responsible for protecting luminaires against these high surge levels, which
can occur in outdoor lighting environments. The SPDs use 3-4 parallel or series connected
high-surge withstand (e.g. 25mm or 34mm diameter) MOVs across the AC lines, as shown
in the green MOV1 block of Figure 11. As shown in that figure, the MOVs are installed from
line to ground, neutral to ground and line to neutral. For installations in regions with severe
lightning exposure, it is common to use parallel connected MOVs for the line to neutral leg.
This will increase differential mode surge capability and the reliability of a luminaire.
When adding this supplemental protection in front of the LED driver, it is very important to
select (MOV1) characteristics that coordinate with those of the existing (MOV2) device in
the driver. The coordination criterion for MOV1 selection is to make sure these larger disc
MOVs in the SPD module clamp first, thereby taking the brunt of the surge energy before
the smaller (MOV2) disc turns on. This will avoid catastrophic current through the driver MOV
and premature opening of the fuse, which happens if the driver MOV turns on first. Therefore,
The MOVs in the SPD module should have a lower max continuous operating voltage rating
than the MOV in the driver.
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Fuse
120V
MOV rated
for 150V rms
continuous
voltage
120V
Load
In this scenario, the 150V rated MOV is subjected to 240V at a limited current, potentially
resulting in thermal run away for the MOV. This potential condition is specifically identified
and addressed in the UL1449 and IEC 61643 Surge Protective Device Standards. As
mentioned earlier in this document, new TMOV technology has been developed that will
aid the designer in protecting against thermal overload in varistors. This in turn provides
protection against:
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TMOV
TMOV
Varistor
MOV Disk
Neutral
TMOV
Ground
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When selecting a TVS diode, the first step is to define the operating parameters of the
circuit to be protected, whether its an LED driver or something else. Table 7 lists the most
important circuit parameters to be considered.
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PLED6
Constant
Current
Source
+
~1.3 V
Active
PLED6
Open
LED
Figure 15. PLEDs protect series wired LED strings should one fail
as an open circuit, the most common failure mode.
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MT1
Control
Circuit
PLED5
ACTIVATED
PLED5
ACTIVATED
PLED5
ACTIVATED
PLED5
ACTIVATED
PLED5
ACTIVATED
PLED5
ACTIVATED
PLED5
ACTIVATED
MT2
MT1
Control
Circuit
MT2
MT1
Control
Circuit
Constant
Current
Source
MT2
MT1
Control
Circuit
MT2
MT1
Control
Circuit
MT2
MT1
Control
Circuit
MT2
MT1
Control
Circuit
MT2
Figure 16. PLEDs also protect LED strings from reverse polarity situations.
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PLED switching current must be less than constant current source value
PLED turn-on voltage must be less than power supply compliance voltage.
Choose how many LEDs in the string (1, 2 or 3) are to be protected by a single PLED. A
Littelfuse PLED6, which triggers at 6 volts, protects one LED; a PLED9, which triggers
at 9 volts, can be used across two LEDs; and a PLED13 can be used with three LEDs.
(Note that when a single PLED is wired across multiple LEDs, a failure of one of those
LEDS will cause the other one or two to go out).
4. Determine the package of the PLED device to fit the lighting environment.
5. Define the ambient temperature of the PLED environment and provide adequate heat
sinking if required.
6. Perform testing on the PLEDs by shunting with the protected LEDs.
Part
Number
V DRM /
Trigger
Voltage
Typica l
# of LEDs
Protected
By-pass
Current
(Maximum)
By-pass
Voltage
(Maximum)
Bypass
Function/
Open LED
Protection
ESD
Protection
Reverse
Battery
Protection
PLED5
5V
500mA
700mA
1.4V 1.8V
Yes
Yes
Yes
QFN22
SOT-89
PLED6
6V
1000mA
1.2V
Yes
No
No
D0214AA,
QFN33
PLED9
9V
1000mA
1.2V
Yes
No
No
D0214AA,
QFN33
PLED13
13V
1000mA
1.2V
Yes
No
No
D0214AA,
QFN33
PLED18
18V
1000mA
1.2V
Yes
No
No
D0214AA,
QFN33
Package
Option
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Material
Typical Use
Copper
Fuse Element
Silver
Nichrome
Resistor Element
Figure 17. Using fusible resistors for overload protection can pose a fire hazard.
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After
Fusing
During Fusing
Fusing Resistor
Overcurrent
Gradual
0.33A-0.825A
Constant
1.65A
Constant
3.2A
Constant
4A
Constant
3.2A
Constant
4A
Constant
3.2A
Constant
4A
Fusing Time
16 min.
5 sec.
n
0.8 sec.
n
0.4 sec.
n
7 sec.
1.7 sec.
8.9 sec.
2.9 sec.
Smoke
Glowing
Fire
Spark
Explode
Discoloration
n
n
Crack
Rupture
Risk of Fire
YES
YES
YES
NO
NO
Table 9. Overcurrent testing results for a fusible resistor and two different fuses made by Littelfuse.
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As shown in Figure 18, the fusible resistor was not able to withstand 40 strikes required
by IEC 61000-4-5 standard. High resistance fusible resistors dissipate excessive heat when
subjected to surge current that is applied in minute intervals. Heat accumulates, which in turn
raises resistor body temperature and resistance. As a result, the fusible resistor opens before
the required 40 surges.
Energy Star test results: Again, fusible resistors were not able to withstand seven strikes
required by the Energy Star standard (Figure 19). Littelfuse test results revealed that fusing
resistors can catch fire, spark, and even explode under abnormal overcurrent conditions,
hence rendering them unsafe. These components generate excessive heat in transient surge
testing causing them to open before the required number of surges are applied, for both IEC
and Energy Star test methods. In a retrofit LED bulb, once the fusible resistor opens, the
bulb will be disconnected from the power source, thus resulting in the failure of EMC testing.
Moreover, the bulb is rendered useless.
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Figure 19. Energy Star surge immunity testing on five different fusible resistors.
The same tests were conducted on 10 and 100 ohm fusible resistors that had nominal 1W
ratings. This was done to determine if their lower 16W fusing power rating would produce
better results. These resistors also failed the IEC and Energy Star tests, and as shown in
Table 10, they also produced a bright glow, generated sparks, and created a fire hazard.
After
Fusing
During Fusing
Overcurrent
Gradual
0.1A-0.3A
Constant
0.4A
Constant
0.57A
Constant
0.8A
Gradual
0.32A-1.28A
Constant
1.26A
Constant
1.79A
Constant
2.53A
Fusing Time
2.1 min.
0.35 sec.
0.007 sec.
0.4 sec.
3.3 min.
11 sec.
n
2 sec.
n
0.008 sec.
n
Smoke
Glowing
Fire
Spark
Explode
Discoloration
Crack
YES
YES
YES
Rated fusing
power
(16W)
32W
64W
Rupture
Risk of Fire
Note
Rated fusing
power
(16W)
32W
64W
Table 10. Overcurrent testing results for 1W 10 and 100 fusible resistors (16W fusing powerrating).
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Figure 20. Progressive destruction of fusible circuit trace intended for overcurrent protection; it ends up igniting the PCB laminate material.
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References
The future is bright for LED lighting technology. As efficiencies increase, thermal
management issues are overcome, quality of light output impresses consumers and
initial costs continue to decline, the technology will continue to proliferate over the next
several years. Double digit growth, both unit shipments and market value are forecasted
power supply manufacturers in designing optimal protection schemes for their driver
modules. At the OEM level we cooperate with luminaire and lamp manufacturers to
5. IEC61000-4-5 specifications
ensure their products are optimally designed for robust surge immunity protection.
When needed we also provide testing services to confirm that designs pass overcurrent
and overvoltage regulatory requirements. We offer a large number of support tools,
including low power consumer lighting protection sample kits, outdoor LED lighting
kits, white papers, application notes, and part selection guides. When requested, our
exceptional application engineering team will supply protection recommendations based
on customer-specific designs.
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Disclaimer
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littelfuse.com
circuitprotection@littelfuse.com
EC128Nv0715