Direct Current (DC) Supply Grids for LED Lighting

Since many alternative energy sources as well as electronics and controls technologies are based
on DC current, DC grids have been investigated more intensely in the last decade. DC grids with
a centralized AC/DC conversion have proven to be advantageous in server farms. While LED
lighting is also a DC current related technology, an obvious choice would be to use DC grids for
them. Prof. Eberhard Waffenschmidt from the Cologne University of Applied Science in
conjunction with Philips Research presents the results of an office building DC lamp system
installation with photovoltaic (PV) support.

Abstract

Most electrical devices operate on direct current (DC) internally, but are supplied by alternating
current (AC). A power supply with DC makes the rectifier electronics unnecessary. This makes
the devices simpler and more reliable and generates less power losses. Especially, if many
identical devices like lamps in supermarkets or open offices are operated, this becomes evident.

This publication aims to show solutions of DC operated professional buildings like offices or
supermarkets and homes. A special focus is put on high voltage supply at 380 Vdc. First, the
component effort for solutions with AC and DC current supply are compared. Especially LED-
lamps can benefit from a DC supply, because lamp drivers can be reduced to a few reliable
components. Then, a loss breakdown including transmission losses is presented. The major
advantage of a DC supply appears, if a micro- grid including decentralized energy generation
and storage is considered. In addition, standardization initiatives working on high voltage DC
grids are listed. Finally, a realized office test bed including DC light emitting diode (LED)
illumination and photovoltaic (PV) support is presented.
Introduction

One trend in lighting is to distribute light sources. This becomes possible with LED lamps,
which offer a small amount but efficient light power. However, this also requires efficient lamp
drivers. Furthermore, assigning each lamp its individual lamp driver becomes a high effort in
material. Therefore, concepts are needed to deal with an increased number of similar lamp
drivers. One solution could be to use a DC power supply. This makes omission of the rectifier
electronics possible, which, in turn, makes the devices simpler, more reliable and generates less
power losses. This is attractive especially in installations where a high number of lamps are
connected to a power rail, like in open space offices or supermarkets (Figure 1). Each lamp
contains an AC to DC conversion circuit, which can be omitted with a DC supply rail. This
becomes particularly attractive if the system is combined with a local photovoltaic generator, as
shown in [1].

DC supply systems are proposed by a number of publications especially for residential

applications, e.g. [2] [3]. But as derived in [4], a large variety of different requirements for
different devices, a DC system for residential applications faces even larger challenges.
Contrarily, in lighting applications the loads are quite similar in their requirements and thus
much better suited for a common DC supply.

Figure 1: Lamp installations in open office space (left) and supermarkets(right)

Effort for AC to DC Conversion

Figure 2 shows the block diagram of a typical lamp driver operated on AC with the parts
necessary for AC to DC conversion. Similar components are necessary for all AC power
supplies.

The rectifier is the essential element and is typically a bridge rectifier consisting of four
diodes. The electrolytic capacitor (elcap) levels out the pulsating rectified sinusoidal voltage.
Recently IEC SC77A WG1 agreed to a new review of the standard IEC 61000-3-2, which means
that in the near future lamp drivers with more than 5 W will require a power factor correction
(PFC) circuit. A PFC ensures that the current drawn from the grid is sinusoidal. The PFC may
consist of an inductor, but this is usually too bulky. Especially for higher power levels a switch
mode converter, typically a step up converter (boost converter) is used. However, this requires a
filter to avoid higher frequency content generated by the switched mode PFC polluting the grid.

Space and components saving

Figure 3 shows a photograph of a Philips Xitanium lamp driver for a 39 W light emitting diode
(LED) lamp as used in the reference setup. In the figure, all parts that are necessary for AC to
DC conversion, are marked. As can be seen, approximately 40% of the printed circuit board
(PCB) is occupied by these components. Especially the PFC and the filter circuit require a lot of
space. The storage elcap is also significant, but the bridge rectifier itself is a comparable small
component.

Figure 2: Typical AC lamp driver

Figure 3: Power driver for a 35 W LED lamp

 DC wide voltage
DC narrow voltage range,
range
Component AC supply mechanical rev. polarity
and reverse polarity
protection
protection
Required Required because of Can be omitted with linear
Filter
because of PFC DC-DC driver
Required for reverse
Rectifier Required Omitted
polarity
Power factor correction Required Required to match
Not necessary
(PFC) / DC-DC converter for P > 25 W wide voltage range
Required to Required because of Can be omitted, if dips are
Elcap storage
avoid flickering dips accepted

Table 1: Overview of required components for AC to DC conversion

As discussed, these components might also be necessary for DC operation. An overview of this
is shown in table 1. The bridge rectifier may be necessary to allow an arbitrary connection of the
DC supply leads. However, this problem may also be solved by a suitable mechanical coding of
the plug to avoid a wrong connection. The elcap may be needed to suppress voltage dips of the
DC supply. However, it should be acceptable for lamps to pass the dips to the lamp and allow a
short flicker. Then an elcap is not necessary.

Figure 4: Power and loss characteristic of a linear current controlled LED driver
If the DC supply voltage has a large variation, it may be necessary to convert it to a constant
level of an intermediate voltage. This requires a DC-to-DC converter, similar to an active PFC.
However, if the DC voltage range has a narrow specification the DC-to-DC converter can be
omitted.

Figure 5: Loss comparison of AC grid (a) and DC grid (b)

The filter is necessary to suppress high frequency contents of switched mode converters. It
becomes necessary if an active PFC is used. If the lamp driver itself uses switched mode
conversion, it remains necessary. However, with a linear lamp driver, even the filter may be
omitted.

In conclusion, the components needed for AC to DC conversion can be omitted if the DC power
plug is mechanically coded, if dips can be accepted, if the voltage is specified in a narrow range
and, optionally, if a linear lamp driver is used.

Linear LED driver

The advantage of a lighting DC supply becomes most obvious with LED lamps. A most simple
“driver” for an LED is simply a resistor. If the supply voltage is very well defined, this would be
the most simple, reliable and durable “lamp driver”. However, if the voltage is less stable, the
brightness of the LED would vary remarkably, because a small voltage variation would already
lead to big changes of the output power.

A solution, nearly as simple, is a linear current driver. A linear current source can easily be built
with one J-FET and one resistor. The efficiency of such a circuit is good and is calculated
assuming a constant forward voltage Ud of the LED and neglecting a residual voltage drop at the
FET. The results are presented in figure 4. As long as the DC supply voltage Us is larger than the
forward voltage Ud, the LED power (blue) is the nominal value. If the supply voltage increases
above Ud, the voltage across the FET rises linearly. The power loss in the FET (orange) increases
proportionally to it. Efficiency (yellow) is calculated from the LED power and the losses.
Figure 6: Loss comparison of AC grid (a) and DC grid (b) with photovoltaic and battery storage
operation

If the voltage variation is within ±10% of the nominal voltage UN (like in the public AC grid),
efficiency can still be above 84%. This simple and reliable circuit can thus achieve similar
efficiency to small-switched mode converters, as long as the voltage range is narrow enough.

Loss savings
The components needed for AC to DC conversion also generate losses. Typically, the smaller the
device, the lower the efficiency. Our own measurements showed losses in the order of 5% of the
output power for lamp drivers. This arrangement is shown in figure 5a. These losses can be
avoided if the device is operated on DC. But if the AC grid supplies the DC grid, an additional
central rectifier is needed. However, this central rectifier can be more efficient due to its larger
size.

Its losses are estimated at about 2% of its output power, as illustrated in figure 5b. In addition,
cable losses can be reduced if a DC voltage of 380 V is used, as shown in figure 7. In total,
losses of about 5% of the output power could be avoided using a 380 V DC grid.

Even larger loss savings can be achieved in a different use case as illustrated in figure 6. It shows
a system that is optimized for self-consumption of photovoltaic (PV) energy. The PV energy
harvested during the day is stored in battery storage and used in the evening.
If all components are connected to the AC grid, losses in the AC to DC (and vice versa)
converters end up to be 10% to 13% of the output power (Figure 6a). In a DC system, these
losses can be completely avoided (Figure 7b). Reference [5] shows a similar result for such a
system, where operation including PV and battery is considered.

Voltage Selection

The supply voltage of the DC grid also has an influence on the losses. Low voltages like 24 V or
48 V have the advantage of being safe to touch and commercially available devices exist.
However, to transmit the same power, much higher current I is necessary compared to 230 V
AC. A high DC voltage like 380 V is compatible to many 230 V AC devices, which operate on a
similar intermediate DC voltage internally.

The power loss Ploss in the cable is proportional to the square of the current
I: Ploss ~ I2. Figure 7 shows the cable losses that appear at different supply voltages, scaled to the
losses at 230 V AC. To achieve the same losses at higher currents, the cable cross sectional area
A must also be scaled proportionately to the current: A ~ I2. Therefore, the same figure 7 shows
the amount of copper that is necessary to achieve the same losses as with the 230 V AC supply.

Organization Topic
Many standards covering low voltage DC grid systems
already
SMB SG4 working group “LVDC distribution systems up to
International Electrotechnical
1500V DC”: Managing new standardization projects at IEC
Commission (IEC)
technical committees (TC)
National standardization working groups. Germany:
TBINK-LVDC working group at DKE/VDE
European standard: EN 300 132-3-1 V2.1.1 (2012-02)
European Telecommunication
Standardisation Institute (ETSI) Value: Definition of DC appliance inrush current limits and
measurement setup
Standardization working group on 380 V DC power grids
for datacenters
EMerge Alliance
Standardization working group on 380 V DC for campus
and microgrids

Table 1: Overview of organizations working on standardization of low voltage DC grids It is

clearly seen that the low voltages of 24 V and 48 V either generate extremely high losses or
require significantly more copper. It also shows that a 380 V DC supply generates only about 1/3
of the losses compared to 230 V AC. It should be noted that insulation properties of 230 V AC
cables are also suitable for 380 V DC operation because they need to withstand the peak voltage.
This safety issue is discussed with other safety issues in more detail in reference [6]. It concludes
that operating at a DC voltage of less than 380 VDC can be considered similar to operating at
230 VAC. A further safety aspect of DC grids discussed is arcing, which mainly appears when a
load is unplugged during operation. Therefore, one must take care that lamps are not exchanged
during operation in a DC system.

Standardization on 380 V DC

The voltage level of 380 V DC is not only attractive for lighting applications, but also for other
applications like the power supply in data centers. A standardized DC supply system will
produce the most advantages. Table 2 gives an overview of the organizations that work on
standardization and their current work.

DC Lighting Demonstration Setup To demonstrate the functionality and to experience the

problems related to it, a DC lighting demonstration is set-up in an office building at Philips
Research in Eindhoven, The Netherlands.

Figure 8 shows a schematic overview of the system.

Figure 8: DC-grid demo installation with solar support and an AC reference grid. Grid voltage:
380 VDC, Solar modules: 2 kWpk, LED lamps: 56 x 37 W, adapted LED drivers, Reference
system: 230 VAC.
The DC part operates on 380 VDC and consists of a rectifier, a 2 kWpk photovoltaic (PV)
generator and 54 LED lamps with 37 W each. The lamps are driven by lamp drivers, which are
adapted to the DC system. Figure 9 shows photographs of the PV panels and of some of the
lamps. The lamps illuminate the floor and are switched on during working hours throughout the
day. In the best case, the PV generator is able to supply all the DC lamps. No feed in of PV
power into the AC grid is [Link] lamps are Philips Xitanium lamps, with drivers modified
for DC operation.

Figure 9: Photos of the reference system: Photovoltaic panels (left), LED- Lamps (right)

A 230 V AC system is also in operation as a reference. Here, the PV power is directly fed into
the mains grid. Furthermore, 18 comparable AC operated Xitanium LED lamps are monitored.

In the DC system the energy drawn from the mains grid is monitored. In the reference AC
system, the energy needed by the lamps (including drivers) and the energy generated by the
photovoltaic system (grid feed in) is monitored. To get a comparison, the needed lamp energy in
the AC system is scaled to the number of lamps in the DC system. The generated PV energy in
the AC system is scaled to the size of the DC PV system and finally both values are subtracted to
achieve a net energy demand comparable to the DC system. Data was measured from April 29th,
2013 until Sept. 6th, 2013. The average power was calculated from the monitored energy. The
results are shown for the DC power demand and the scaled AC power demand in figure 10.
There are two gaps in the data resulting from failures and maintenance time, which are not
considered for the final comparison. The figure shows that the power demand of the DC system
is always lower than that of the comparable AC system. In total, the DC system demand was
2132.6 kWh, while 2181.4 kWh relate to the scaled AC system. In conclusion, the DC system
energy demand was 2.24% lower than the comparable AC system.
Figure 10: Comparison of total consumption in the DC system and the AC reference system. The
energy in the AC system is scaled to the DC system

Conclusion

Operating lamps and other devices with a residential DC grid offers two major benefits:

Overall power losses can be reduced. However, for a supply of the residential DC grid from a
public AC grid, this effect is partly compensated by losses in the central rectifier. But energy
savings become especially visible with the integration of additional local power sources.

As a further benefit, complexity can be reduced in the powered devices by shifting it into the
infrastructure. This can make the devices more durable and reliable. Especially for mass products
like lamp drivers and consumer devices, which are manufactured and used in a huge number, this
will reduce the overall cost.

From a system point of view, it is advantageous to make those devices, which are needed in large
numbers as simply and cheaply as possible and to allow a few central devices to be more
complex. This cost advantage should be considered as the main benefit of the DC system.

The specification of a DC system should take these benefits into account: To reduce losses in the
distribution system and the voltage should be as high as possible. For lamps, an operating
voltage like 380 V DC is proposed.
To allow the reduction of complexity, the definition of a narrow voltage tolerance is required.
References

[1] Ulrich Boeke, Matthias Wendt, Lennart Yseboodt, "Combined Solar and AC Mains Powered
LED Light-ing System", 14th European Conference on Power Electronics and Applications
(EPE'11), Birminham, United Kingdom, [Link].-[Link].2011.

[2] T.-F. Wu, Y.-K. Chen, G.-R. Yu, Y.-C. Chang, "Design and Development of DC-Distributed
System with Grid Connection for Residential Applications", 8th International Conference on
Power Electronics - ECCE Asia, May 30-June 3, 2011, The Shilla Jeju, Korea, paper no. TuF1-4.

[3] Rakwichian Wattanapong, “Community Smart Grid for ASEAN Decentralize Power”,
Presentation at World Alternative Energy Forum, Chiang Mai, Thailand, 12.-14. Dec. 2012.
(Online available (29.6.2014) at [Link] )

[4] Bernhard Scheeren, “Optionen für eine Gleichstromversorgung in einem Wohnhaus“,

Masterthesis at Cologne University of Applied Science, Institute for Electrical Power
Engineering, Cologne, Germany and Zuyd Hogeschool, Heerlen, The Netherlands, 16. April
2014.

[5] Suponthana Wuthipong, „MW Scale Stand-Alone PV Hybrid Mini Grid System”,
Presentation at World Alternative Energy Forum, Chiang Mai, Thailand, 12.-14. Dec. 2012.
(Online available (29.6.2014) at [Link] )

[6] Jung-Hoon Ahn, Dong-Hee Kim, Byoung-Kuk Lee, Hyun-Cheol Jin, Jae-Sun Shim, "DC
Appliance Safety Standards Guideline through Comparative Analysis of AC and DC Supplied
Home Appliances", Journal of Electrical Engineering & Technology Vol. 7, No. 1, 2012, pp.
51~57, Online available (29.6.2014) at: [Link]