EB1108

EV4027-J-00A
Universal Input, 7W
Primary-side-control with Active PFC Offline
WLED Driver Evaluation Board For A19 Bulb
DESCRIPTION
FEATURES
The EV4027-J-00A Evaluation Board is
designed to demonstrate the capabilities of
MP4027. The MP4027 is a primary-side-control
offline LED lighting controller which can achieve
high power factor and accurate LED current for
an isolated lighting application in a single stage
converter. It works in boundary conduction
mode for reducing the MOSFET and Diode
switching losses.


The EV4027-J-00A is typically designed for
driving an isolated 7W A19 LED bulb with
20VTYP, 350mA LED load at universal input
(90V~265VAC, 50/60Hz).
The EV4027-J-00A has high performances in
efficiency, line/load regulation and meets
IEC61547 surges, IEC61000-3-2 Class C
harmonics and EN55015 conducted EMI. It has
multi-protection function as over-voltage
protection, short-circuit protection, primary-side
OCP, NTC, etc.
ELECTRICAL SPECIFICATION
Parameter
Input Voltage
Output Voltage
LED Current
Output Power
Efficiency (full load)
PF
Symbol
Value
Units
VIN
VOUT
ILED
POUT
90 ~ 265
20
350
7
VAC
V
mA
W
η
84~87
%











Small IC package: SOT23-8
Real current control without secondaryfeedback circuit
Good line/load regulation
High power factor>0.9 over universal input
voltage
Boundary conduction mode improves
efficiency
NTC function
PWM dimming available
Input UVLO
Primary-side over current protection
Over-voltage protection
Short-circuit protection
Over-temperature protection
Fit inside A19 bulb enclosure
APPLICATIONS



Solid State Lighting
Industrial & Commercial Lighting
Residential Lighting
All MPS parts are lead-free and adhere to the RoHS directive. For MPS
green status, please visit MPS website under Quality Assurance. “MPS” and
“The Future of Analog IC Technology”, are Registered Trademarks of
Monolithic Power Systems, Inc.
Warning: Although this board is designed to satisfy safety
requirements, the engineering prototype has not been
agency approved. Therefore, all testing should be performed
using an isolation transformer to provide the AC input to the
prototype board.
>0.9
EV4027-J-00A Rev. 1.1
www.MonolithicPower.com
9/9/2013
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© 2013 MPS. All Rights Reserved.
1
EV4027-J-00A– EVB DESCRIPTION
EV4027-J-00A EVALUATION BOARD
(L x W x H) 66mm x 22.6mm x 23mm
Board Number
MPS IC Number
EV4027-J-00A
MP4027GJ
EVALUATION BOARD SCHEMATIC
Figure 1 - Schematic
EV4027-J-00A Rev. 1.1
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9/9/2013
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© 2013 MPS. All Rights Reserved.
2
EV4027-J-00A– EVB DESCRIPTION
PCB LAYOUT (DOUBLE-SIDED)
Figure 2 - Top Layer
Figure 3 - Bottom Layer
EV4027-J-00A Rev. 1.1
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9/9/2013
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© 2013 MPS. All Rights Reserved.
3
EV4027-J-00A– EVB DESCRIPTION
CIRCUIT DESCRIPTION
The EV4027-J-00A is configured in a singlestage Flyback topology, it uses primary-sidecontrol which can mostly simplify the schematic
and et a cost effective BOM. It can also achieve
high power factor and accurate LED current.
F1, RV1, CX1, L1 , L2, L3, C2 and BD1
compose the input stage. F1 fuses the AC input
to protect for the component failure or some
excessive short events. RV1 is used to absorb
the high ring voltage of surge test, L1, L2, CX1,
L3, R1, R2, R3 and C2 associated with CY1 form
the EMI filter which can meet the requirement for
universal input. The diode rectifier BD1 rectifies
the input line voltage. Small bulk CBB capacitor
C2 is used for a low impedance path for the
primary switching current, to maintain high power
factor, the capacitance of C4 should be selected
with low value.
R5, R6, C4 provide sine wave reference for the
primary peak current to get an active PFC
function. The divided voltage should be lower
than the max voltage rating of MULT pin.
R4, C3, D2, R15 are used to supply the power for
MP4027. A 4.7μF ceramic capacitor C3 is
selected to maintain the supply voltage. At startup, C3 is first charged up by the starter resistor
R4 from the line voltage, when the VCC voltage
passes the turn on threshold the IC starts to work
and the gate begins to switch, then the VCC
power supply is taken over by the auxiliary
winding through R15, D2.
R9, R10, D4, C1 are used to detect the auxiliary
winding to get the transformer magnetizing
current zero crossing signal for realizing the
boundary conduction operation, and also monitor
the output OVP condition. The OVP voltage is set
by the divider ratio of R9, R10. D4 is used to
block the negative plateau voltage of auxiliary
winding when MOSFET is turn on. C1 is used to
decouple the high frequency noise influence on
CS/ZCD pin.
R11, R12 are primary sensing resistors for
primary side current control. The value of R11,
R12 set the output LED current. R7 is used to
form a feedforward from input line voltage to
optimize the line regulation. C6, R14, D3 are
used to damp the leakage inductance energy so
the drain voltage can be suppressed at a safe
level.
NTC is a 220kΩ thermistor to set the thermal
protection point, C7 is used to absorb the high
frequency noise in NTC pin.
Diode D1 rectifies the secondary winding voltage
and the capacitor C8, C9 are the output filter.
The resistor R13 is placed as pre-load to limit the
output voltage rise too high in open load
condition.
EV4027-J-00A Rev. 1.1
www.MonolithicPower.com
9/9/2013
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© 2013 MPS. All Rights Reserved.
4
EV4027-J-00A– EVB DESCRIPTION
EV4027-J-00A BILL OF MATERIALS
Qty
Ref
Value
Description
1
BD1
MB6S
BRIDGE, 600V, 0.5A
1
1
1
1
1
C1
C2
C3
C4
C5
10pF/50V
100nF/400V
4.7μF/50V
2.2nF/50V
1μF/10V
1
C6
22nF/630V
1
C7
2.2nF/50V
2
C8,C9
330μF/35V
1
1
CX1
CY1
1
D1
2
1
D2,D4
D3
22nF/275V
2.2nF
MBRS3200
T3G
BAV21W
S1ML
1
F1
250V/2A
Inductor,1.5
mH
ISU04N65A
1
1
1
1
1
1
1
1
1
1
1
1
L1,L2,
l3
Q1
R1,R2
,R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
1
RV1
1
T1
RM6
1
1
U1
NTC
MP4027
220kΩ
3
1
3
5.1kΩ
470k
5.23kΩ
1MΩ
43kΩ
20Ω
2.2kΩ
9.53kΩ
1.8Ω
1.1Ω
30kΩ
100kΩ
100Ω
TVR10431K
SY
Ceramic Cap,C0G,50V
CBB, 104/400V
Ceramic Cap,X7R,50V
Ceramic Cap,X7R,50V
Ceramic Cap,X7R,10V
Ceramic
Cap,X7R,630V
Ceramic Cap,X7R,50V
Electrolytic
Capacitor;35V;
Electrolytic
X Capacitor,275V
Y Capacitor,4000V
0603
DIP
1206
0603
0603
Manufacturer
Taiwan
Semiconductor
murata
Panasonic
murata
TDK
murata
1206
TDK
C3216X7R2J223K
0603
TDK
C1608X7R1H222K
DIP
Jianghai
DIP
DIP
PX223K3IB19L270D9R
JNK12E222MY02N
Diodes,200V,3A
SMB
Caili
Hongke
ON
Semiconductor
Diodes
Diodes
COOPER
BUSSMANN
Diodes,200V,0.2A
Diodes,1000V,1A
Package
SOIC-4
SOD-123
SMA
Manufactuer_P/N
MB6S
GRM1885C1H100JA01
CBB 0.1μF/400V
GRM31CR71H475KA12L
C1608X7R1H222K
GRM188R71A105KA61D
CD263-35V330
MBRS3200T3G
BAV21W-7-F
Taiwan Semiconductor
SS-5-2A
DIP
Inductor,15mH/0.21A
DIP
TDK
TSL0808RRA-152KR21
650V/4A
TO-251
IPS
ISU04N65A
RES,1%
1206
Yageo
DIP,0.5W RESISTOR
Film RES, 1%
DIP,0.25W RESISTOR
Film RES,1%
Film RES, 1%
Film RES, 1%
Film RES, 1%
RES, 1%
Film RES, 1%
Film RES, 1%
Film RES,5%
Film RES, 1%
DIP
0603
DIP
0603
0603
0603
0603
1206
1206
1206
1206
1206
any
Yageo
any
LION
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
430V/2500A
DIP
TKS
TVR10431KSY
RM6
EMEI
FX0314
FCTSOT-8
0603
MPS
murata
RM6,
Np:Ns:Naux=115:23:26
, Lp=2.18mH
LED Lighting Controller
NTC Thermistor
SS-5-2A
RC1206FR-075K1L
RC0603FR-075K23L
RC0603FR-0743KL
RC0603FR-0720RL
RC0603FR-072K2L
RC0603FR-079K53L
RC1206FR-071R8L
RC1206FR-071R1L
RC1206FR-0730KL
RM12JTN104
RC1206FR-07100RL
MP4027GJ-Z
NCP18WM224E03RB
EV4027-J-00A Rev. 1.1
www.MonolithicPower.com
9/9/2013
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© 2013 MPS. All Rights Reserved.
5
EV4027-J-00A– EVB DESCRIPTION
TRANSFORMER SPECIFICATION
Electrical Diagram
RM6
1
N4
Pri.
57Ts
Φ0.17mm
NC1
N1
Pri.
W1
23Ts
Φ0.30mm
T.I.W
B1
58Ts
Φ0.17mm
2
6
N2
Bias
N3
Sec.
26Ts
Φ0.14mm
AUX+1
6
E2: 0.025mm×6mm
Winding Start
Figure 4 – Transformer Electrical Diagram
Notes:
1. Don’t connect NC, AUX+, W and B to any pin of Bobbin.
2. E is a copper adhered to the core’s periphery, and connected to pin6.
Winding Diagram
Pin. Side
Top. Side
3Ts
1Ts
N4
N3
1Ts
1Ts
N2
N1
Bobbin
Figure 5 – Winding Diagram
EV4027-J-00A Rev. 1.1
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9/9/2013
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EV4027-J-00A– EVB DESCRIPTION
Winding Order
Winding No.
N1
N2
N3
N4
Tape Layer Number
1
1
1
3
Start & End
2→NC
AUX+→6
W→B
NC→1
Magnet WireΦ(mm)
0.17
0.14
0.30 (T.I.W)
0.17
Turns
58
26
23
57
Electrical Specifications
Electrical Strength
Primary Inductance
Primary Leakage Inductance
2 seconds, 60Hz, from Pins 1, 2, 6, AUX+ to W, B
Pins 1- 2, all other windings open, measured at 50kHz, 0.1
VRMS
Pins 1-2 with pins 6, AUX+ W, B shorted, measured at
60kHz, 0.1 VRMS
3000VAC
2.18mH±8%
20μH±10%
Materials
Item
1
2
3
4
5
6
7
8
9
10
Description
2
Core: RM6, UI=2500±25%, AL=184.5H/N ±3% GAP, ACME P4 or equivalent
Bobbin: RM6, 3+3PIN RMMOVE PIN6 1SECT TH, PM9630 UL94V-0
Wire: Φ0.17mm, Φ0.14mm, 2UEW, CLASS B or equivalent
Triple Insulation Wire: Φ0.30mm,TRW(B) or equivalent
Tape: 6.5mm(W)×0.06mm(TH)
Tape: 7.0mm(W)×0.06mm(TH)
Copper: 6.0mm(W)×0.025mm(TH)
Varnish: JOHN C. DOLPH CO, BC-346A or equivalent
Adhesive: 400-36 or equivalent
Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent
EV4027-J-00A Rev. 1.1
www.MonolithicPower.com
9/9/2013
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© 2013 MPS. All Rights Reserved.
7
EV4027-J-00A– EVB DESCRIPTION
EVB TEST RESULTS
Performance Data
VIN(VAC)
PIN(W)
Vo(V)
I6LEDs(A)
Po(W)
Efficiency
PF
I5LEDs(A)
I4LEDs(A)
I3LEDs(A)
90
100
110
120
135
150
170
185
200
220
230
240
250
265
7.89
7.81
7.79
7.76
7.74
7.72
7.71
7.73
7.75
7.79
7.81
7.86
7.88
7.95
19.45
19.44
19.44
19.44
19.44
19.44
19.44
19.44
19.44
19.44
19.44
19.44
19.43
19.43
0.344
0.344
0.344
0.344
0.345
0.345
0.345
0.345
0.345
0.345
0.345
0.345
0.346
0.346
6.69
6.69
6.69
6.69
6.71
6.71
6.71
6.71
6.71
6.71
6.71
6.71
6.72
6.72
84.80%
85.63%
85.85%
86.18%
86.65%
86.88%
86.99%
86.76%
86.54%
86.09%
85.87%
85.33%
85.31%
84.56%
0.987
0.987
0.985
0.982
0.977
0.971
0.961
0.953
0.945
0.931
0.922
0.914
0.906
0.901
0.347
0.347
0.347
0.348
0.348
0.348
0.348
0.349
0.349
0.349
0.349
0.349
0.35
0.35
0.35
0.351
0.351
0.351
0.351
0.351
0.352
0.352
0.353
0.353
0.353
0.353
0.353
0.354
0.354
0.354
0.355
0.355
0.355
0.355
0.356
0.356
0.357
0.357
0.356
0.358
0.358
0.358
Harmonic Data
The design passes EN6100-3-2 Class C requirement.
110V
Harmonic
Order
Limit
(Active input
power <25W)
Content
mA
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
57.12
31.92
16.80
8.40
5.88
4.98
4.31
3.80
3.40
3.08
2.81
2.59
2.40
2.23
2.09
1.96
1.85
1.75
1.66
72.31
9.74
1.99
0.63
1.02
1.12
1.06
0.92
0.73
0.50
0.28
0.07
0.13
0.28
0.39
0.45
0.48
0.45
0.42
0.32
Test Result
(Pass/Fail)
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
230V
Harmonic
Order
Limit
(Active input
power <25W)
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
28.80
16.09
8.47
4.24
2.96
2.51
2.17
1.92
1.72
1.55
1.42
1.30
1.21
1.12
1.05
0.99
0.93
0.88
0.84
mA
Content
Test Result
(Pass/Fail)
36.42
7.57
2.56
1.22
0.76
0.64
0.56
0.51
0.43
0.34
0.28
0.22
0.18
0.14
0.17
0.20
0.20
0.22
0.24
0.23
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
EV4027-J-00A Rev. 1.1
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
8
EV4027-J-00A– EVB DESCRIPTION
Electric Strength Test
Primary circuit to secondary circuit electric strength testing was completed according to IEC61347-1
and IEC61347-2-13.
Input and output was shorted respectively. 3750VAC/50Hz sine wave applied between input and output
for 1min, and operation was verified.
Surge Test
Line to Line 500V and Line to Power Earth 1kV surge testing was completed according to IEC61547.
Input voltage was set at 230VAC/50Hz. Output was loaded at full load and operation was verified
following each surge event.
Surge Level
(V)
Input Voltage
(VAC)
Injection Location
Injection Phase
(°)
Test Result
(Pass/Fail)
500
-500
1000
-1000
1000
-1000
230
230
230
230
230
230
L to N
L to N
L to PE
L to PE
N to PE
N to PE
90
270
90
270
90
270
Pass
Pass
Pass
Pass
Pass
Pass
EV4027-J-00A Rev. 1.1
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9/9/2013
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9
EV4027-J-00A– EVB DESCRIPTION
EVB TEST RESULTS
Performance waveforms are tested on the evaluation board.
6 LEDs in series, ILED=350mA, VOUT=20V, LP=2.18mH, Np:NS:NAUX =115:23:26.
EV4027-J-00A Rev. 1.1
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9/9/2013
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© 2013 MPS. All Rights Reserved.
10
EV4027-J-00A– EVB DESCRIPTION
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
6 LEDs in series, ILED=350mA, VOUT=20V, LP=2.18mH, NP:NS:NAUX =115:23:26.
EV4027-J-00A Rev. 1.1
www.MonolithicPower.com
9/9/2013
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© 2013 MPS. All Rights Reserved.
11
EV4027-J-00A– EVB DESCRIPTION
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
6 LEDs in series, ILED=350mA, VOUT=20V, LP=2.18mH, NP:NS:NAUX =115:23:26.
EV4027-J-00A Rev. 1.1
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9/9/2013
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12
EV4027-J-00A– EVB DESCRIPTION
QUICK START GUIDE
1. Preset AC Power Supply to 90VAC  VIN 265VAC.
2. Turn Power Supply off.
3. Connect the LED string between “LED+” (anode of LED string) and “LED-” (cathode of LED string).
4. Connect Power Supply terminals to AC VIN terminals as shown on the board.
5. Turn AC Power Supply on after making connections.
6. For PWM dimming demo, remove NTC thermistor and C7, apply a >200Hz PWM dimming signal on
NTC pin, make sure the PWM signal has same GND with primary circuit GND.
NOTICE: The information in this document is subject to change without notice. Please contact MPS for current specifications.
Users should warrant and guarantee that third party Intellectual Property rights are not infringed upon when integrating MPS
products into any application. MPS will not assume any legal responsibility for any said applications.
EV4027-J-00A Rev. 1.1
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
13
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