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www. cree.com/xlamp c opyright ? 2010 c ree, inc. a ll rights reserved. the information in this document is subject to change without notice. cree, the cree logo and xl amp are registered trademarks of cree, inc. cl d- ap 72 rev 0b cree ? xlamp ? a19 reference overview cree, inc. 4600 silicon drive durham, nc 27703 us a tel: +1.919.313.5300 application note other trademarks, product and company names are the property of their respective owners and do not imply specifc product and/or vendor endorsement, sponsorship or association. c opyright ? 2011-2012 c ree, inc. a ll rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and x lamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com. introduction w ithin the past year the le d industry has begun producing white, high power leds in suffcient volume that value-priced light bulbs are now practical consumer products. in north a merica many retailers now have le d bulbs as part of their inventory of lighting products. most le d replacement lamps or le d light bulbs pose signifcant design problems in managing thermal equilibrium. these problems were always less severe for gas discharge and flament lamps because these lamps are inherently convective and dissipate heat through the same path as the light. le ds, whose thermal load the 3 snow cones table of contents introduction ........................................................ 1 a19 lighting r equirements ................................... 2 design goals ....................................................... 6 estimate effciencies ............................................ 7 implementations and analysis .............................. 10 conclusions ....................................................... 12 reliance on any of the information provided in this application note is at the users sole risk. cree and its affliates make no warranties or representations about, nor assume any liability with respect to, the information in this document or any le d-based lamp or luminaire made in accordance with this reference design, including without limitation that the lamps or luminaires will not infringe the intellectual property rights of c ree or a third party. l uminaire manufacturers who base product designs in whole or part on any cree a pplication note or r eference design are solely responsible for the compliance of their products with all applicable laws and industry requirements.
2 is dissipated through conduction, must have a separate path and heat sink for thermal dissipation. hence the design constraints that come with replacement lamps. a great deal of interest and activity has centered on the e26/a 19 form factor and there are many ways to approach the design and production of the classic a 19 bulb. this application note reviews a variety of le d choices available from cree to achieve attractive and cost effective warm white a 19 bulbs or replacement lamps. this application note is different from other c ree application notes in that it reviews a spectrum of design choices rather than focusing on a particular implementation. while most c ree reference designs or application notes use a 6-step framework, described in the led l uminaire design guide, 1 this application note is largely about the many le d options and topologies that are available when designing a19 led replacement lamps. a s such we only visit a few of the steps in the framework. a19 lighting requirements the most common form of a19 le d replacement lamps are often referred to as snow cones. this moniker comes from the hemispheric dome that covers a circuit board of le ds that sit atop a conic heat sink, which gives the visual impression of an ice cream cone or snow cone. the benefts of this approach come from a relatively large set of suppliers, delivering form-factor appropriate heat sinks, device drivers and molded diffusers. a s such, this style of a 19 bulb has rapidly become the dominant value-priced bulb. for many lighting applications the hemispheric distribution of luminous fux that comes along with the snow cone approach is suffcient C a very wide-angle food lamp. but for applications that require a spherical or omnidirectional distribution of fux, the snow cone is not optimal. 2 in order to achieve an omnidirectional fux distribution, other approaches to fux geometry must be used. noteworthy or innovative examples of these designs include bulbs from ge, philips and lsg, shown below. 1 led luminaire design guide, application note ap15, www.cree.com/xlamp_app_notes/luminaire_design_guide. the guide advocates a 6-step approach consisting of: 1. defne lighting requirements 2. defne lighting goals 3. estimate effciencies of optical, thermal and electrical systems 4. calculate the number of leds needed 5. consider all the design possibilities and choose the best 6. complete the fnal steps 2 the us environmental protection agency defnes the omnidirectional requirements in energy star? program requirements for integral led lamps, www.energystar.gov/ia/partners/product_specs/program_reqs/ill_prog_reqs.pdf. table 4, p3, applies to all lamps; table 6, p9, applies to non-standard lamps C snow cone bulbs fall into this category, and table 7a, p10, applies to omnidirectional lamps. xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
3 figure 1: omnidirectional bubls from ge, lsg and phillips 3 the following table summarizes requirements to be met to be eligible to qualify for the energy star? p rogram. characteristic requirement cct the lamp must have one of the following designated cc ts (per ansi c78.377-2008) consistent with the 7-step chromaticity quadrangles below. 2700 k 3000 k 3500 k 4000 k color maintenance the change of chromaticity over the frst 6,000 hours of luminaire operation shall be within 0.007 on the cie 1976 (u, v) diagram. cri minimum cri (r a) of 80. r 9 value must be greater than 0. dimming l amps may be dimmable or non-dimmable. product packaging must clearly indicate whether the lamp is dimmable or not dimmable. m anufacturers qualifying dimmable products must maintain a w eb page providing dimmer compatibility information. w arranty 3-year warranty for luminaires with replaceable drivers. a llowable lamp bases m ust be a lamp base listed by ansi. p ower factor ( pf) lamp power < 5 w and low voltage lamps: no minimum pf lamp power > 5 w : pf > 0.7 minimum o perating temperature -20c or below led o perating frequency led operating frequency 120 hz note: this performance characteristic addresses problems with visible ficker due to low frequency operation and applies to steady-state as well as dimmed operation. dimming operation shall meet the requirement at all light output levels. 3 the illustration shows the ge energy smart led bulb, a 40-w equivalent lsg defnity a19 bulb and the phillips endura bulb. xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
4 characteristic requirement electromagnetic and r adio frequency interference must meet appropriate fcc requirements for consumer use (fcc 47 cfr p art 15) a udible noise class a sound rating transient protection p ower supply shall comply with ieee c62.41-1991, class a operation. the line transient shall consist of seven strikes of a 100 khz ring wave, 2.5 k v level, for both common mode and differential mode. o perating v oltage l amp shall operate at rated nominal voltage of 120, 240 or 277 vac, or at 12 or 24 vac or vdc. table 1: energy star requirements for all integral led lamps this table summarizes the energy star requirements for non-standard led lamps. characteristic requirement minimum luminous effcacy led lamp power < 10 w : 50 lm/w led lamp power > 10 w : 55 lm/w minimum light output 200 lumens l uminous intensity distribution no specifc distribution is required. must submit goniophotometry report showing luminous intensity distribution produced by the lamp. lumen maintenance l70 > 25,000 hours r apid-cycle stress test c ycle times must be 2 minutes on, 2 minutes off. l amp will be cycled once for every 2 hours of required minimum l 70 life. table 2:energy star requirements for non-standard led lamps the following table summarizes the energy star requirements for omnidirectional lamps. characteristic requirement minimum luminous effcacy led lamp power < 10 w : 50 lm/w led lamp power > 10 w : 55 lm/w minimum light output 200 lumens nominal wattage of lamp to be replaced (watts) 25 35 40 60 75 100 125 150 minimum initial light output of led lamp (lumens) 200 325 450 800 1100 1600 2000 2600 xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
5 characteristic requirement l uminous intensity distribution p roducts shall have an even distribution of luminous intensity (candelas) within the 0 to 135 zone (vertically axially symmetrical). l uminous intensity at any angle within this zone shall not differ from the mean luminous intensity for the entire 0 to 135 zone by more than 20%. at least 5% of total fux (lumens) must be emitted in the 135-180 zone. distribution shall be vertically symmetrical as measured in three vertical planes at 0, 45 and 90. maximum lamp diameter not to exceed target lamp diameter as per ansi c78.20-2003. maximum overall length (mol) not to exceed mol for target lamp as per ansi c78.20-2003. lumen maintenance l70 > 25,000 hours r apid-cycle stress test c ycle times must be 2 minutes on, 2 minutes off. l amp will be cycled once for every 2 hours of required minimum l70 life. c olor angular uniformity the variation of chromaticity shall be within 0.004 from the weighted average point on the cie 1976 (u, v) diagram. table 3: energy star requirements for omnidirectional lamps the performance system performance requirements for non-standard and omnidirectional lamps, as shown in tables 3 and 4, are essentially the same. the latter has defned luminous intensity distribution and minimum light output, which allow the lamps to be compared more readily to the incandescent lamps they replace. xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
6 design goals to be familiar with the rapidly evolving product space for le d replacement lamps, application engineers at c ree have built at least a dozen different a19 lamp prototypes. our team has experimented with a broad selection of xlamp leds, drivers and enclosures. we have developed a few examples as models as being the most cost-effective, for a variety of reasons. for example: constraint solution rationale maximize driver effciency xlamp m x-6s high voltage leds in series all for more- effcient driver implementations m inimize led in bulb bom xlamp xp-e hew extremely high lumen/$ ratio, optimized for diffused lighting applications m inimize p roduction and inventory costs xlamp cxa -2011 reduced manufacturing complexity; simplifed inventory table 4: a19 design goals and led solutions we will explore aspects of each of these designs. figure 2: a19 bulbs using a variety of cree xlamp leds the 3 snow cones xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
7 the table below summarizes characteristics and goals from several bulb designs we review in this application note. all these designs use hemispheric distribution and are considered non-standard led lamps in the e nergy star vernacular. characteristic unit 40-w-equivalent value bulb 60-w-equivalent performance bulb luminaire light output lm 450 800 p ower w <10 <13 effcacy lm/w >50 65 lifetime hours 25,000 cct k 3,000 3,000 cri 80 80 table 5: general a19 system goals estimate efficiencies of the optical, thermal & electrical systems this section is an estimation exercise and discussion for a variety of led confgurations using c rees product c haracterization tool or pc t. 4 the pc t is tool that models basic led and system performance to develop initial approaches for system design. in all the cases we review here, we are assuming a 15% loss in the diffusing structures of the le d bulbs. this is a representative loss for the cast-plastic diffusive domes. for a 40- w -equivalent le d bulb we have set up the pc t to compare system estimation information for three le ds, the xlamp m x-6s, m x-6 and xp-e hew . the settings of the pct are to deliver 450 lumens with an 85%-effcient optical system and an 87%-effcient driver system. w e also assume we have a heat sink that allows the system to maintain a 55 solder-point temperature. we have confgured the pct display to focus on system-wide information, looking at the number leds required, lumens delivered, system wattage and effcacy. 4 pct.cree.com xlamp xp-e hew led xlamp mx-6 led xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
8 figure 3: product characterization tool analysis of a 450-lumen a19 bulb this analysis shows us many approaches to delivering a 40- w -equivalent value bulb. in considering drive current and number of le ds, at one end of the spectrum the four m x-6s le ds can present an 85- v , 100-m a load, consume just under 10 watts of power and deliver just under 50-lm/w effcacy. six mx-6 leds driven at 350 ma deliver over 63 lm/w while using under 8 watts of power. four xp-e hew leds, in the r2 fux bin, can deliver equivalent fux at an improved effcacy of just over 70 lm/w using 6.9 w of power. the case for using m x-6s le ds is particularly interesting and not well represented in figure 3 because the high- voltage leds have the potential to allow for higher-effciency device drivers. in an article in the april 2011 issue of leds magazine , matt r eynolds of national semiconductor shows through a simple and elegant analysis that the use of high-voltage le ds allows for lower operating temperatures of supporting driver electronics capacitors, inductors and diodes. 5 the implication of his analysis includes the potential for drivers that are both more reliable (cooler operating temperatures for capacitors, for example) and more effcient. in our pct analysis, an increase of 6% effciency in drive electronics, from 87% to 93%, delivers an almost 7% improvement in effcacy. 5 reynolds, matthew, high led drive currents with low stack voltages creat effciency challenges, leds magazine, february, 2011, pp 53-59. figure 3 compare: 11 13 12 15 2 syst em: 450 85% 87% model 15 model 14 model 21 flux 3 100.0 flux 6 93.9 flux 7 114.0 price - $ 2.0 55 price - $ 2.0 55 price - $ 2.0 55 1 1 1 sys # led sys lm tot sys w sys lm/w sys # led sys lm tot sys w sys lm/w sys # led sys lm tot sys w sys lm/w 0.100 4 466 9.61 48.5 17 450.5 5.47 82.4 17 477.7 5.28 90.5 0.110 4 500 10.76 46.5 16 464 5.7 81.4 15 460.5 5.17 89.1 0.120 4 532.8 11.91 44.7 15 471 5.86 80.4 14 466.2 5.31 87.8 0.130 4 563.2 13.06 43.1 14 473.2 5.95 79.5 13 466.7 5.23 89.2 0.140 4 591.2 14.25 41.5 13 470.6 6.13 76.8 12 460.8 5.24 87.9 0.150 3 463.2 11.55 40.1 12 463.2 6.07 76.3 11 451 5.18 87.1 0.160 3 481.8 12.45 38.7 11 451 5.94 75.9 11 478.5 5.56 86.1 0.170 3 498.6 13.31 37.5 11 477.4 6.32 75.5 10 461 5.4 85.4 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.300 #n/a #n/a #n/a #n/a 7 506.8 7.64 66.3 6 464.4 5.93 78.3 0.350 #n/a #n/a #n/a #n/a 6 497.4 7.86 63.3 6 532.2 6.97 76.4 0.400 #n/a #n/a #n/a #n/a 5 464 7.7 60.3 5 498 6.72 74.1 0.450 #n/a #n/a #n/a #n/a 5 512 8.79 58.2 5 551 7.64 72.1 0.500 #n/a #n/a #n/a #n/a 5 557.5 10 55.8 4 481.6 6.85 70.3 0.550 #n/a #n/a #n/a #n/a 4 481.2 8.97 53.6 4 520.8 7.63 68.3 0.600 #n/a #n/a #n/a #n/a 4 514.4 9.93 51.8 4 558.8 8.37 66.8 0.650 #n/a #n/a #n/a #n/a 4 546 10.94 49.9 4 594.8 9.1 65.4 0.700 #n/a #n/a #n/a #n/a 4 575.6 11.95 48.2 3 472.2 7.41 63.7 current (a) current display range: led mult iple led mult iple led mult iple opt ical efficiency: elect rical efficiency: target lumens : led 1 led 2 led 3 cree xlamp mx-6s {cw/ww} q4 [100] fine (0.1a - 0.7a) cree xlamp mx-6 {cw/ww} q3 [93.9] cree xlamp xp-e hew {cw/nw/ww} r2 [114] sys # led sys lm tot sys w sys lm/w tsp (oc) tsp (oc) tsp (oc) x1 x1 x1 xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
9 figure 4: improved driver performance for the mx-6s led the choices change when moving to the brighter 60- w -equivalent le d lamp. v ery high effcacies can be achieved with large numbers of leds, but it is an impractical amount of money to be spent on le ds, and the space constraints of the bulb will not permit it. in practice, the 800-lumen target is achieved with a few additional parts and with an increased thermal load in the system. for this part of the exercise, we are assuming a higher junction temperature of 85 c . the two cost-effective le ds for this bulb are the xp-e hew and the cxa2011. the pct is again confgured to illustrate numbers of leds, system lumens, system power and effcacy. figure 4 compare: 11 13 12 15 2 syst em: 450 85% 93% model 15 model 1 model 1 flux 3 100.0 flux 1 0.0 flux 1 0.0 price - $ 2.0 55 price - $ 1.0 25 price - $ 1.0 25 1 1 1 sys # led sys lm tot sys w sys lm/w 0.100 4 466 8.99 51.8 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.110 4 500 10.06 49.7 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.120 4 532.8 11.14 47.8 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.130 4 563.2 12.22 46.1 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.140 4 591.2 13.33 44.4 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.150 3 463.2 10.81 42.8 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.160 3 481.8 11.65 41.4 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.170 3 498.6 12.45 40 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.180 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.190 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a 0.200 #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a #n/a current (a) current display range: led mult iple led mult iple led mult iple opt ical efficiency: elect rical efficiency: target lumens : led 1 led 2 led 3 cree xlamp mx-6s {cw/ww} q4 [100] fine (0.1a - 0.7a) (none) (none) sys # led sys lm tot sys w sys lm/w tsp (oc) tj (oc) tj (oc) x1 x1 x1 xlamp xp-e hew led xlamp cxa2011 led xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
10 figure 5: led confgurations for a 60-w-equivalent, non-directional led lamp running at these space-constrained and elevated temperatures, it takes eight xp-e hew leds from the r2 fux bin, driven at 350 ma to deliver 810 lumens, at 12 watts of power with an effcacy of almost 68 lm/w. the single cxa2011 from the j fux bin, running at 250 ma delivers improved performance: 814 lumens, 11.3 watts and over 72 lm/w. implementations and analysis the most thorough analysis of a cree led a 19 bulb comes from a collaboration with m arvell semiconductor (www. marvell.com). the 40-watt-equivalent le d replacement lamp uses four c ree xp-e hew le ds and m arvells 88em8081 pfc controller. the system delivers 475 lumens at 3000 k cc t, consuming 7.5 watts of power. 6 this implementation is in good correspondence with the pct analysis in figure 3. 6 details on this design are available at www.marvell.com/green-technology/marvell_cree_a19led_reference_bulb_platform_ brief_pb001.pdf xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
11 figure 6: 4 xp-e hew leds in a 40-w-equivalent a19 lamp in early 2011, c ree built a cxa20011-based a 19 bulb. in fact, in analyzing some a 19 replacement lamps on the market, we found one with a device driver that closely matched the cxa2011 voltage and current requirements, and as a frst pass replaced the led array with a cxa2011. results from this frst experiment were somewhat disappointing. at steady-state, the bulb produced 750 lumens and consumed 12.8 watts with a system effcacy of 58 lm/w. although this level of performance is e nergy star conformant, it was not in good correspondence with the pc t analysis shown in figure 5. we believe refnements to the heat sink assembly and a more recent driver circuit could deliver a substantial improvement in performance. figure 7: a19 bulb with a cxa2011 led figure 6 figure 7 xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.
12 conclusions because of their small size and lumen density, development of cost-effective and well-engineered le d replacement lamps presents tremendous challenges to every aspect of led systems design. experimentation and innovation are occurring throughout the le d replacement lamp ecosystem. c ree supports this ecosystem by delivering the broadest portfolio of le ds in the industry and by maintaining a vigorous pace of product innovation to bring the best le d options to the replacement-lamp manufacturing community. reliance on any of the information provided in this application note is at the users sole risk. cree and its affliates make no warranties or representations about, nor assume any liability with respect to, the information in this document or any le d-based lamp or luminaire made in accordance with this reference design, including without limitation that the lamps or luminaires will not infringe the intellectual property rights of c ree or a third party. l uminaire manufacturers who base product designs in whole or part on any cree a pplication note or r eference design are solely responsible for the compliance of their products with all applicable laws and industry requirements. xlamp a19 reference design copyright ? 2011-2012 cree, inc. all rights reserved. the information in this document is subject to change without notice. cree ? , the cree logo and xlamp ? are registered trademarks of cree, inc. for product specifcations, please see the data sheets available at www.cree.com. for warranty information, please contact cree sales at sales@cree.com.

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