EV4060-K-00A 198VAC~265VAC/50Hz, 72V/125mA Non-isolated with Active PFC TRIAC Dimmable LED Driver Evaluation Board The Future of Analog IC Technology DESCRIPTION FEATURES The EV4060-K-00A Evaluation Board is designed to demonstrate the capabilities of MP4060. The MP4060 is a TRIAC dimmable LED controller with excellent dimming performance. The dimming control method is optimized for high input AC voltages ranging from 198VAC to 265VAC. • It works in boundary conduction mode for reducing the MOSFET and Diode switching losses. Its adaptive dimmer type detection and phase-cut-based dimming control can achieve good dimmer compatibility and deep dimming range. The active bleeder control circuit is integrated in BD pin to simplify the external bleeder design. The EV4060-K-00A is typically designed for driving a 9W Triac dimmable LED bulb with 72VTYP, 125mA LED load from 198VAC to 265VAC, 50Hz. The EV4060-K-00A has an excellent efficiency and meets IEC61547 surge immunity, IEC61000-3-2 Class C harmonics and EN55015 conducted EMI requirements. It has multi-protection function as over-voltage protection; winding short circuit protection; output short-circuit protection; over-temperature protection; integrated thermal foldback etc. ELECTRICAL SPECIFICATION Parameter Symbol Value Units Input Voltage Output Voltage VIN VOUT 198 to 265 72 VAC V LED Current Output Power Efficiency (full load) Power Factor THD ILED POUT η PF THD 125 9 >85 >0.78 <36 mA W % • • • • • • • • • • • • • Adaptive Dimmer Type Detection and Phase-Cut-Based Dimming Control Active Bleeder Control Circuit Integrated Good Dimmer Compatibility and Deep Dimming Range Fast Start-Up without Perceptible Delay Integrated Thermal Current Foldback to Prolong the LED Lifetime Accurate Line & Load Regulation High Power Factor Operates in Boundary Conduction Mode Cycle-by-Cycle Current Limit Winding Short-Circuit Protection Output Over-Voltage Protection Output 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, halogen 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. % EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 1 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER EV4060-K-00A EVALUATION BOARD (L x W x H) 49.5mm x 26.4mm x 16.9mm Board Number MPS IC Number EV4060-K-00A MP4060GK EVALUATION BOARD SCHEMATIC Figure 1—Schematic EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 2 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER PCB LAYOUT (SINGLE-SIDED) Figure 2—Top Layer Figure 3—Bottom Layer EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 3 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER CIRCUIT DESCRIPTION The EV4060-K-00A is configured in a singlestage Buck-boost topology and gets a cost effective BOM. It achieves high power factor and excellent TRIAC dimming performance. FR1, R2, RV1 and BD1 compose the input stage. The fusible resistor FR1 fuses the AC input to protect the component failure or some excessive short events, its resistance associated with R2 are used as a passive damper of dimming. RV1 is used for surge test. The diode rectifier BD1 rectifies the input line voltage. R1, R7 are sensing resistors for current control. The value of R1 and R7 set the output LED current. Diode D3 is the output rectifying diode. The capacitor C7 is the output filter. The resistor R10 is placed as a dummy load to consume the output power in open load condition. The C9 is used to help improve the EMI performance. D4, D5, D6, D7, Q2, R12, R14, R15, C10 with the control signal BD compose the active bleeder circuit. The circuit is enabled when dimming condition is detected, it monitors the input current by resistor R11 and provides bleeding current through resistor R12 when the input current drops to low, so the input current will be kept in a high level to maintain the TRIAC dimmer turn on and avoid any random flickers. C1, L1 and C2 form a π EMI filter. C8, R13 are used as a passive bleeder which also help keep the TRIAC current above the minimum holding current after TRIAC turns on. R3, R4, C3 provide sine wave reference for the current control loop to get an active PFC function. R16, D2 and C4 are used to supply the power for MP4060. A 22μF electrolytic capacitor C4 is selected to maintain the supply voltage. At startup, C4 is first charged up through the external MOSFET Q1 and internal charging circuit, when the VCC voltage reaches VCCEN, the internal charging circuit stops charging. Then the power supply is taken over by the auxiliary winding through R16, D2. R5, C5, D1, and D8 are used for the gate drive of the external MOSFET Q1. R6 is used to adjust the driver capability for better EMI and small power loss. R8 and R9 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 R8 and R9. EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 4 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER EV4060-K-00A BILL OF MATERIALS Qty Ref 2 C1, C2 1 C3 3.3nF/50V 1 C4 22uF/50V 1 C5 470nF/25V 1 C6 2.2uF/10V 1 C7 330uF/80V 1 C8 220nF/450 V 1 C9 10nF/630V 1 C10 10nF/50V 1 C11 1 D1 NS RLZTE1118D Zener Diode;16.82V;10mA; 1 D2 DSF1J Diode;600V;1A 1 ES1J S1JL 1 D3 D4, D5, D6 D7 1N4148W Diode;75V;0.15A SOD-123 Diodes 1N4148W 1 D8 1N4148WS SOD-323 Diodes 1N4148WS-7-F 1 BD1 MB6S SOIC-4 Taiwan semi 1 L1 3mH DIP Hulsin 1 Q1 ISU04N65A Diode;75V;0.15A Rectifier Bridge;600V;0.5A HDR0608-302M N-Channel Mosfet 650V;4A TO-252 IPS ISU04N65A 1 Q2 3DD13001 Mosfet;400V;0.2A TO-92 JIANGSU CHANGJIANG 3DD13001 1 Q3 NS 1 R1 6.8Ω Film Resistor;1% 0805 Yageo 3 Value 100nF/450 V Description Package Manufacturer DIP Fala C222S104K30C000 0603 TDK C1608X7R1H332K DIP Jianghai 0603 muRata 0603 muRata DIP YMIN LK 330uF/80V DIP Fala C222S224K31C000 1206 muRata 0603 muRata LLDS ROHM Diode;600V;1A SOD123FL SMA SHENXINYUA N MCC ES1J Diode;600V;1A SMA Taiwan semi S1JL CBB;450V Ceramic Capacitor;50V;X7R Electrolytic Capacitor;50V Ceramic Capacitor,25V;X7R Ceramic Capacitor;10V;X7R Electrolytic Capacitor;80V CBB;450V Ceramic Capacitor;630V;X7R Ceramic Capacitor;50V;X7R Manufactuer_P/N CD281L-50V22 GRM188R61E474KA1 2 GRM188R71A225KE1 5D GRJ31BR72J103KWJ 1L GRM188R71H103KA0 1D RLZTE-1118D DSF1J MB6S HDR0608-302M RC0805FR-076R8L 1 R2 51Ω/1W Resistor;1%;1W DIP any 51Ω /1W 2 R3, R5 1MΩ/0.25W Resistor;1%;1/4W DIP any 1MΩ /1W 1 R4 4.02kΩ Film Resistor;1% 0603 Yageo RC0603FR-074K02L 1 R6 30Ω Film Resistor;1% 0805 Yageo RC0805FR-0730RL 1 R7 2Ω Film Resistor;1% 0805 Yageo RC0805FR-072RL 1 R8 249kΩ Film Resistor;1% 0603 Yageo RC0603FR-07249KL 1 R9 68.1kΩ Film Resistor;1% 0603 Yageo RC0603FR-0768K1L 1 R10 R11, R16 100kΩ Film Resistor;1% 1206 Yageo RM12JTN104 20Ω Film Resistor;1% 1206 Yageo RC1206FR-0720RL 2 EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 5 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER EV4060-K-00A BILL OF MATERIALS (continued) Qty Ref Value 1 R12 6.8kΩ/1W 1 R13 1 Description Package Manufacturer Manufactuer_P/N Resistor;1%;1W DIP any 6.8kΩ/1W 510Ω/1W Resistor;1%;1W DIP any 510Ω/1W R14 2kΩ Film Resistor;1% 0603 Yageo RC0603FR-072KL 1 R15 11.3kΩ Film Resistor;1% 0603 Yageo RC0603FR-0711K3L 1 R17 0Ω Film Resistor;1% 1206 Yageo RC1206FR-070RL 1 R18 NS 1 1 FR1 RV1 39Ω/1W TVR07431 DIP DIP Yageo any FKN1WSJT-52-39R TVR07431 1 T1 EE13 DIP Emei 1 U1 MP4060 Fuse Resistor;5% MOV L=1.56mH, Np:Naux=182:54 TRAIC Dimmable, Offline LED Lighting Controller MSOP10 MPS 4 L,N,LED+, LED- 1.0 公针 MP4060GK 1.0 公针 EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 6 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER TRANSFORMER SPECIFICATION Electrical Diagram Figure 4—Transformer Electrical Diagram Winding Diagram Pin Side 2Ts 2Ts 1T Pin Side N2 N1 Bobbin Figure 5—Winding Diagram EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 7 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER Winding Order Winding No. N1 N2 Tape Layer Number 1 2 2 Start & End Magnet WireΦ(mm) Turns 2→1 4→3 0.25mm * 1 0.15mm*1 182 54 Electrical Specifications Electrical Strength Inductance 60 second, 60Hz, from Windings to CORE. Pins 2 - 1, all other windings open, measured at 60kHz, 0.1 VRMS 1000VAC 1.56mH±8% Materials Item 1 2 3 4 5 6 Description Core: EE13, UI=2500±25%, ACME P4 or equivalent Bobbin: EE13, 5+5PIN, REMOVE PIN5,6,8,9,10 Wire: Φ0.25mm, Φ0.15mm , 2UEW, CLASS F or equivalent Tape: 6.5mm(W)×0.06mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 8 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER EVB TEST RESULTS Performance Data Efficiency, PF and THD f (Hz) 50 Vin(V) Pin(W) Vo(V) Io(mA) Po(W) Efficiency(%) PF THD(%) 198 10.74 74.20 124.9 9.267 86.29 0.891 24.0 210 10.78 74.20 125.3 9.297 86.25 0.876 25.4 220 10.82 74.20 125.6 9.319 86.13 0.859 26.8 230 10.88 74.20 125.9 9.341 85.86 0.843 28.4 240 10.92 74.20 126.2 9.364 85.75 0.826 30.1 250 10.96 74.20 126.5 9.386 85.64 0.811 32.5 265 11.05 74.20 127.0 9.423 85.28 0.789 35.4 Dimming Compatibility (No flicker and shimmer with these 17 different Dimmers) Dimmer No. Manufacturer Dimming Type Imax (mA) Imin (mA) 1 MIKA 433/4 60-400W Leading 126 28 2 Busch 2250U 600W Leading 126 13 Berker 283010 60-400W 3 Leading 126 17 4 JUNG 225 NV DE 20-500W/VA Leading 126 10 5 Berker 286610 20-500W Leading 126 16 T46s 20~315W Trailing 127 18 40-400W Leading 126 14 6 LICHTREGLER Part No. Power Stage 7 EMC PROP400U 8 Busch 2247U 500W/VA Leading 126 18 9 Busch 2200 60-400W Leading 126 22 10 Busch 6513 U-102 420W/VA Trailing 127 11 11 JUNG 225 NV DE 20…500W/VA Leading 126 17 12 MIKA 433 HAB 20-315W Trailing 127 14 MIKA? EIM-585 20-300W Trailing 127 1 Busch 6519U 550W/VA Trailing 127 10 JUNG 225 TDE 20…525W Trailing 127 12 16 SIEMENS 5TC8 284 20-600W Trailing 127 10 17 JUNG 266 GDE 60…600W Leading 126 15 13 14 15 EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 9 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER Electric Strength Test 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 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 -500 230 230 L to N L to N 90 270 Pass Pass Thermal Test MOSFET Q1: 60.1℃ Without dimmer Bleeder Resistor R13: 137℃ Leading edge dimmer with 50% turn on phase Output diode D3: 57.7℃ Without dimmer Active Bleeder Resistor R12: 85.1℃ Trailing edge dimmer with 90% turn on phase EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 10 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VIN=230VAC/50Hz, 24 LEDs in series, ILED=125mA, VOUT=72V. EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 11 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN=230VAC/50Hz, 24 LEDs in series, ILED=125mA, VOUT=72V. EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 12 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN=230VAC/50Hz, 24 LEDs in series, ILED=125mA, VOUT=72V. EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 13 EV4060-K-00A – HIGH LINE VOLTAGE, 9W APFC DIMMABLE LED DRIVER QUICK START GUIDE 1. Preset AC Power Supply to 198VAC ≤ 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 (“L” and “N”) as shown on the board. 5. Turn AC Power Supply on after making connections. NOTICE: The information in this document is subject to change without notice. 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. EV4060-K-00A Rev.1.0 www.MonolithicPower.com 5/25/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 14