EV4056-S-00A 108VAC~132VAC/60Hz, 50V/200mA Low Cost, Non-isolated with Active PFC TRIAC Dimmable LED Driver Evaluation Board The Future of Analog IC Technology DESCRIPTION FEATURES The EV4056-S-00A Evaluation Board is designed to demonstrate the capabilities of MP4056. The MP4056 is a non-isolated, TRIAC dimmable LED controller with active PFC and excellent dimming performance. • • 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 EV4056-S-00A is typically designed for driving a 10W TRIAC dimmable LED bulb with 50VTYP, 200mA LED load from 108VAC to 132VAC, 60Hz. The EV4056-S-00A has a cost effective BOM and excellent efficiency. It 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; ZCD pin short protection; over-temperature protection etc. ELECTRICAL SPECIFICATION Parameter Symbol Value Units Input Voltage Output Voltage LED Current VIN VOUT ILED 108 to 132 50 200 VAC V mA Output Power Efficiency (full load) Power Factor THD POUT η PF THD 10 >85 >0.93 <20 W % • Single Winding Inductor Adaptive Dimmer Type Detection and Phase-Cut-Based Dimming Control Good Dimmer Compatibility and Deep Dimming Range Fast Start-Up without Perceptible Delay 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 ZCD Pin Short 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. % EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER EV4056-S-00A EVALUATION BOARD (L x W x H) 56mm x 22mm x 19mm Board Number MPS IC Number EV4056-S-00A MP4056GS EVALUATION BOARD SCHEMATIC Figure 1—Schematic EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER PCB LAYOUT (SINGLE-SIDED) Figure 2—Top Layer Figure 3—Bottom Layer EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER CIRCUIT DESCRIPTION The EV4056-S-00A is configured in a singlestage Buck-boost topology and gets a cost effective BOM with using single winding inductor. It achieves high power factor and excellent TRIAC dimming performance. F1, RV1, L1 and BD1 compose the input stage. F1 fuses the AC input to protect the component failure or some excessive short events. RV1 is used for surge test. L1 is a high frequency common mode filter. The diode rectifier BD1 rectifies the input line voltage. C1, L2 and C3 form a π EMI filter. C2, R4 are used as a passive bleeder which helps keep the TRIAC current above the minimum holding current after TRIAC turns on. R5, R6, C4 provide sine wave reference for the current control loop to get an active PFC function. D1 and C5 are used to supply the power for MP4056. A 22μF electrolytic capacitor C5 is selected to maintain the supply voltage. At startup, C5 is charged up through Q1, D1 and the internal charging circuit, when the VCC voltage reaches VCCEN, the internal charging circuit stops charging. Then the power supply is charged by Q1, D1 during the switching off time. R7, C6, D2, and D3 are used for the gate driver of the external MOSFET Q1. R8 is used to adjust the driver capability for better EMI and small power loss. C8, R1, R2 and D4 are used to detect the inductor L3 magnetizing current zero crossing signal for realizing the boundary conduction operation. C8 is a high-pass filter for the magnetizing signal. D4 is used to clamp the signal steady status voltage. R1, R2 are used to limit the current flow to D4 and ZCD pin. R9, R10 are sensing resistors for current control. The value of R9 and R10 set the output LED current. Diode D5 is the output rectifying diode. The capacitor C9 is the output filter. The resistor R3 is placed as a dummy load to consume the output power in open load condition. The sidactor D6 is used to limit the output maximum voltage in open load condition. The CY1 is a Y-cap, used to help improve the EMI performance. EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER EV4056-S-00A BILL OF MATERIALS Qty Ref Value 1 BD1 MB6S 1 C1 100nF/450V Description BRIDGE, 600V, 0.5A CBB,450V Package Manufacturer Manufactuer_P/N SOIC-4 Taiwan Semi MB6S DIP Fala 1 C2 330nF/250V CBB,250V DIP Haimenyinyan 1 C3 150nF/450V CBB,450V Ceramic Cap,X7R,50V Electrolytic Capacitor;50V Ceramic Cap,X7R,25V Ceramic Cap,10V,X7R Ceramic Cap,1000V Electrolytic Capacitor, 63V Y Capacitor,2500V Diode,75V,0.15A Zener Diode,16.82V, 10mA Zener Diode, 3.9V, 5mA Diode,400V,1A DIP Fala 1 C4 4.7nF/50V 0603 muRata GRM188R71H472KA01D 1 C5 22uF/50V DIP Jianghai CD281L-50V22 1 C6 470nF/25V 0603 muRata GRM188R71E474KA12D 1 C7 2.2uF/10V 0805 muRata GRM21BR71A225KA01L 1 C8 22pF/1000V 1206 muRata GRM31A5C3A220JW01D 1 C9 220uF/63V DIP Rubycon 220uF/63V 1 CY1 2.2nF/250V DIP Hongke JNK12E222ML02N 2 D1, D2 1N4148W SOD-123 Diodes 1N4148W 1 D3 RLZ TE-11 18D SOD-123 ROHM RLZ TE-11 18D 1 D4 BZT52C3V9 SOD-123 Diodes BZT52C3V9 1 D5 ES1G SMA PREMIER 1 D6 P640SB Sidactor,77V SMA 1 F1 250V/1A Fuse DIP any 1 L1 Emei TP4U300-00 L2 DIP Wurth 7447724472 1 L3 EE13 EE13 Emei FX0393 1 Q1 CED830G TO-251 CET CED830G 1 R1 10kΩ TP4U300-00 Inductor,4.7mH/0 .21A EE13,Np=160,Lp =750uH N-Channel MOSFET, 500V, 4.5A Film Resistor, 1% DIP 1 300uH/1A Inductor,4.7m H 0603 Yageo 1 R2 30kΩ Film 'Resistor,1% 0805 LIZ 1 R3 30kΩ Film 'Resistor,1% 1206 Yageo 1 R4 330Ω Resistor,5%,2W DIP any 1 R5 7.5kΩ 0603 Yageo 1 R6 1MΩ Film 'Resistor,1% Resistor,5%,0.25 W DIP any LEAD EMC C222S104K30C000 CL21XX C222S154K30C000 ES1G P640SB 250V/1A RC0603FR-0710KL CR05T05NJ30K RC1206FR-0730kL 330Ω/2W RC0603FR-077K5L 1MΩ/0.25W EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER EV4056-S-00A BILL OF MATERIALS (continued) Qty Ref Value 1 R8 51Ω 1 R7 470kΩ/0.5W Description Package Manufacturer Film 'Resistor,1% Resistor;5%;0.5 W 0603 Yageo DIP any Film 'Resistor,1% 1206 Yageo Manufactuer_P/N RC0603FR-0751RL 470kΩ/0.5W 1 R9, R10 RV1 TVR07241 240V/2500A DIP TKS TVR07241 1 U1 MP4056GS MP4056GS SOIC8 MPS MP4056GS R3 2 500mΩ RC1206FR-070R5L EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER TRANSFORMER SPECIFICATION Electrical Diagram Figure 4—Transformer Electrical Diagram Winding Diagram Pin Side Pin Side 2Ts N1 1T Figure 5—Winding Diagram EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER Winding Order Winding No. N1 Tape Layer Number 1 2 Start & End Magnet WireΦ(mm) Turns 1→10 0.3mm * 1 160 Electrical Specifications Electrical Strength Inductance 60 second, 60Hz, from Winding to CORE. Pins 1 - 10, all other windings open, measured at 60kHz, 0.1 VRMS 1000VAC 750uH±8% Materials Item 1 2 3 4 5 6 Description Core: EE13, UI=2500±25%, ACME P4 or equivalent Bobbin: EE13, 5+5PIN, REMOVE PIN2,3,4,6,7,8,9 Wire: Φ0.3mm, 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 EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER EVB TEST RESULTS Performance Data Efficiency, PF and THD f (Hz) 60 Vin(V) Pin(W) Vo(V) Io(mA) Po(W) Efficiency(%) PF THD(%) 108 11.49 50.20 198.0 9.940 86.51 0.964 18.3 120 11.46 50.20 198.0 9.940 86.73 0.955 19.4 132 11.46 50.20 199.0 9.990 87.17 0.936 19.9 Dimming Compatibility (No flicker and shimmer with these 29 different Dimmers) Dimmer No. Manufacturer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 LUTRON LUTRON LUTRON LUTRON LUTRON LUTRON LUTRON LEVITON LEVITON LUTRON LEVITON LUTRON LUTRON LUTRON LUTRON LUTRON LEVITON LUTRON LUTRON LEVITON LUTRON LUTRON LUTRON LUTRON 25 LUTRON 26 27 28 29 LUTRON LUTRON COOPER LEVITON Part No. Q-600P-IV CN-600P AY-600P SLV-600P LG-600P 6B38-Q-600P GL-600H-DK 1G40O5 1I20O5 GLV02-F06392 6633-P 6B38-S-600P CT-600P 6B38-S-603PG 6B38-DV-600P 6B38-DVLV-600P 1L10O5 GLS01-C06570 DV-600P-BR C20-6684-IW AY-600P-LA TG-600PH-WH TG-603GH-WH S-600 DVPDC-203P-WH S-600P 6B38-DV-603PG 6B28 6633-P-1G10O5 Power Stage Imax (mA) Imin (mA) 600W Incandescent 600W 600W 600W 600W 600W 600W Incandescent 600W 600W 600W 600W 600W 600W 600W 600W 600W 600W 600W 600W Incandescent 600W Incandescent 600W Incandescent 600W 600W 600W 200W for Philips dimmable CFL 600W 600W 600W 600W 201 200 200 200 200 200 200 200 200 200 200 200 200 166 200 199 199 167 199 199 200 200 200 199 2 5 8 8 5 9 3 0 0 0 0 1 3 5 3 10 0 0 4 0 13 10 9 2 199 31 199 165 199 199 1 6 0 1 EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W 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 120VAC/60Hz. 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 -500 120 120 L to N L to N 90 270 Pass Pass Thermal Test Output Diode D5: 57.8℃ Bleeder Resistor R4: 90.9℃ Without dimmer Leading edge dimmer with 50% turn on phase EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VIN=120VAC/60Hz, 16 LEDs in series, ILED=200mA, VOUT=50V. EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN=120VAC/60Hz, 16 LEDs in series, ILED=200mA, VOUT=50V. EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN=120VAC/60Hz, 16 LEDs in series, ILED=200mA, VOUT=50V. EV4056-S-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 EV4056-S-00A – LOW LINE VOLTAGE, 10W APFC DIMMABLE LED DRIVER QUICK START GUIDE 1. Preset AC Power Supply to 108VAC ≤ VIN ≤132VAC. 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. EV4056-S-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