EB1106

EV4026-J-00B
Universal Input, 20W
Primary-side-control with Active PFC Offline
WLED Driver Evaluation Board for PAR38 Bulb
DESCRIPTION
FEATURES
The EV4026-J-00B Evaluation Board is
designed to demonstrate the capabilities of
MP4026. The MP4026 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 EV4026-J-00B is typically designed for
driving an isolated 20W PAR38 LED bulb with
40VTYP, 500mA LED load at universal input
(90V-265VAC, 50/60Hz).
The EV4026-J-00B 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, etc.
ELECTRICAL SPECIFICATION
Parameter
Input Voltage
Output Voltage
LED Current
Output Power
Efficiency (full load)
Symbol
Value
Units
VIN
VOUT
ILED
POUT
90 -265
40
500
20
VAC
V
mA
W
η
87~90
%
PF
>0.9
THD
<20









Small IC package: Thin SOT23-6
Real current control without secondaryfeedback circuit
Good line/load regulation
High power factor>0.9 over universal input
voltage
Boundary conduction mode improves
efficiency
Input UVLO
Primary-side over current protection
Over-voltage protection
Short-circuit protection
Over-temperature protection
Fit inside PAR38 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.
%
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
1
EV4026-J-00B– EVB DESCRIPTION
EV4026-J-00B EVALUATION BOARD
(L x W x H) 83.5mm x 30.0mm x 23mm
Board Number
MPS IC Number
EV4026-J-00B
MP4026GJ-Z
EVALUATION BOARD SCHEMATIC
Figure 1 - Schematic
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
2
EV4026-J-00B– EVB DESCRIPTION
PCB LAYOUT (DOUBLE-SIDED)
Figure 2 - Top Layer
Figure 3 - Bottom Layer
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
3
EV4026-J-00B– EVB DESCRIPTION
CIRCUIT DESCRIPTION
The EV4026-J-00B is configured in a singlestage FLYBACK topology, it uses primary-sidecontrol which can mostly simplify the schematic
and get a cost effective BOM. It can also achieve
high power factor and accurate LED current.
F1, RV1, CX1, L1 , L2, L3, L4, 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, L4, 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
C2 should be selected with low value.
R5, R6, R17, 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
MP4026. A 4.7μF electrolytic 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, D2, 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. D2 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.
Diode D1 rectifies the secondary winding voltage
and the capacitor C7, C8 are the output filter.
The resistor R13 is placed as pre-load to limit the
output voltage rise too high in open load
condition.
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
4
EV4026-J-00B– EVB DESCRIPTION
EV4026-J-00B BILL OF MATERIALS
Qty
1
Ref
BD1
Value
KBP206
1
C1
10pF
1
C2
220nF/630V
1
C3
4.7μF/50V
1
C4
5.6nF/50V
1
C5
1μF/16V
1
C6
10nF/630V
330μF/50V
1
1
1
1
1
C7,
C8
CX1
CY1
D1
D2
D3
47nF/275VAC
1nF/4kV
MURS340T3
BAV23A
WSRGC10MH
1
D4
BZT52C30
1
1
1
F1
JP1
JR1
L1,
L2,
L3
250V/3.15A
0Ω
0Ω
1
L4
300μH
1
Q1
SMK0870F
R1,
R2
R3
R4
R5
R6,
R14,
R17
R7
R8
R9
R10
10kΩ
2
3
2
1
1
1
3
1
1
1
1
Package
DIP
Manufacturer
Bangdayuan
0603
Murata
DIP
Panasonic
ECQE6224KF
DIP
Jianghai
CD287-50V4.7
0603
muRata
GRM188R71H562KA01D
0805
Murata
GRM21BR71C105KA01
1206
TDK
DIP
Jianghai
CD263-50V330(10*16)
DIP
DIP
SMC
SOT-23
1206
Carli
Hongke
ON Semi
Jianfu
ZOWIE
PX473K3IB29L270D9R
JNK09E102MY02N
MURS340T3
BAV23A
WSRGC10MH
SOD-123
Diodes
BZT52C30
DIP
COOPER
SS-5-3.15A
1206
Yageo
RC1206FR-070RL
DIP
Wurth
768772102
DIP
EMEI
TP4U300-00
TO-220F
AUK
SMK0870F
Film Resistor;1%
1206
Yageo
RC1206FR-0710KL
1kΩ
300kΩ
7.32kΩ
Film Resistor;1%
Film Resistor;5%,1W
Film Resistor;1%
1206
DIP
0603
Yageo
Any
Yageo
RC1206FR-071KL
499kΩ
Film Resistor;1%
1206
Yageo
RC1206FR-07499KL
1.6MΩ
51Ω
1.87kΩ
8.66kΩ
Film Resistor;5%
Film Resistor;5%
Film Resistor;1%
Film Resistor;1%
0603
0805
0603
0603
Yageo
Yageo
Yageo
Yageo
RC-03L165JT
RC0805JR-0751RL
RC0603FR-071k87L
RC0603FR-078k66L
1mH
Description
BRIDGE, 600V, 2A
Ceramic Capacitor,
50V, COG
Capacitor;630V;
CBB
Electrolytic Capacitor;
50V;105℃
Ceramic Capacitor;
50V;X7R
Ceramic Capacitor,
16V, X7R
Ceramic Capacitor,
630V, X7R
Electrolytic Capacitor;
50V;105℃
X2 Capacitor, 275V
Y1 Capacitor, 4kV
Diode, 3A, 400V
Diode, 0.2A, 200V
Diode, 1kV, 1A
Zener Diode, 30V,
2mA
Fuse, 250V, 3.15A
Wire
Film Resistor;1%
Inductor, 1mH, 0.5A
Common
Choke,
300μH, 1A
N-Channel MOSFET,
700V, 8A
Manufactuer_P/N
KBP206
GRM1885C1H100JAO1
C3216X7R2J103K
RC0603FR-077K32L
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
5
EV4026-J-00B– EVB DESCRIPTION
EV4026-J-00B BILL OF MATERIALS (continued)
Qty
1
1
1
1
1
1
Ref
R11
R12
R13
R15
R16
RV1
Value
1.1Ω
500mΩ
30kΩ
20Ω
1.5Ω
TVR10431KSY
1
T1
FX0319
1
U1
MP4026
Description
Film Resistor;1%
Film Resistor;1%
Film Resistor;1%
Film Resistor;1%
Film Resistor;1%
430V, 2500A
EFD25;LP=950μH;
NP:NS:NAUX:NShielding
=81:27:17:60
Offline LED Lighting
Controller
Package
1206
1206
1206
1206
1206
DIP
Manufacturer
Yageo
Yageo
Yageo
Yageo
Yageo
TKS
Manufactuer_P/N
RC1206FR-071R1L
RC1206FR-070R5L
RC1206FR-0730KL
RC1206FR-0720RL
RC1206FR-071R5L
TVR10431KSY
EFD25
EMEI
FX0319
FCTSOT-6
MPS
MP4026GJ-Z
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
6
EV4026-J-00B– EVB DESCRIPTION
TRANSFORMER SPECIFICATION
Electrical Diagram
1
3
N5
N1
W
2
4
N3
B
N2
5
Sec. Side
Float
WINDING START
N4
4
Pri. Side
Figure 4 – Transformer Electrical Diagram
Notes: 1. N4 is shielding winding, float Float pin in the winding.
Winding Diagram
3Ts
1T
N5
N4
1T
N3
1T
N2
1T
N1
Figure 5 – Winding Diagram
Winding Order
Winding No.
N1
N2
N3
N4
N5
Tape Layer Number
1
1
1
1
3
Start & End
2→3
5→4
W→B
4→Float
3→1
Magnet WireΦ(mm)
0.25*2
0.18*1
0.35*2 (T.I.W)
0.15*1
0.25*2
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
Turns
57
17
27
60
24
7
EV4026-J-00B– EVB DESCRIPTION
Electrical Specifications
Electrical Strength
Primary Inductance
Primary Leakage Inductance
1 second, 50Hz, from Pins 1, 2, 4, 5 to W, B
Pins 1- 2, all other windings open, measured at 40kHz,
0.25 VRMS
Pins 1-2 with pins 4, 5 W, B shorted, measured at 100kHz,
0.1 VRMS
2500VAC
950μH±8%
20μH±10%
Materials
Item
1
2
3
4
5
6
7
8
9
Description
2
Core: EFD25, UI=2300, AL=179.0nH/N ±3% GAPPED, ACME P4
Bobbin: EFD25, 5+5PIN SECT T-H T375J UL94V-0
Wire: Φ0.25mm, Φ0.18mm, Φ0.15mm, UEWF, CLASS B
Triple Insulation Wire: Φ0.35mm,TRW(B)
Tape: 17.0mm(W)×0.06mm(TH), Yellow
Tube:#22 Black
Varnish: BC-346A
Epoxy: E-500
Solder Bar: SN99.5/Cu0.5
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
8
EV4026-J-00B– EVB DESCRIPTION
EVB TEST RESULTS
Performance Data
f
(Hz)
60
50
VIN
(VAC)
90
100
110
120
135
150
170
185
200
220
230
240
250
265
PIN
(W)
22.08
21.92
21.82
21.74
21.66
21.63
21.61
21.64
21.68
21.74
21.77
21.81
21.86
21.95
VOUT
(V)
39.40
39.40
39.40
39.40
39.40
39.40
39.40
39.40
39.40
39.40
39.40
39.40
39.40
39.40
I12LEDs
(mA)
489.0
490.0
491.0
492.0
492.0
492.0
492.0
492.0
492.0
492.0
492.0
492.0
492.0
493.0
POUT
(W)
19.27
19.31
19.35
19.38
19.38
19.38
19.38
19.38
19.38
19.38
19.38
19.38
19.38
19.42
η
(%)
87.3
88.1
88.7
89.2
89.5
89.6
89.7
89.6
89.4
89.2
89.0
88.9
88.7
88.5
PF
0.997
0.997
0.996
0.995
0.993
0.989
0.983
0.978
0.972
0.962
0.956
0.950
0.943
0.933
I11LEDs
(mA)
493
494
494
494
494
494
494
495
495
495
495
495
495
495
I10LEDs
(mA)
496
497
497
497
498
498
498
498
498
498
498
498
498
499
I9LEDs
(mA)
499
500
500
500
500
500
500
501
501
501
501
501
502
502
I8LEDs
(mA)
502
502
503
503
503
504
504
504
504
504
505
505
505
506
I7LEDs
(mA)
506
506
506
506
506
506
506
507
507
507
508
508
508
508
I6LEDs
(mA)
509
510
510
509
509
509
508
508
508
508
508
508
508
508
Harmonic Data
The design passes EN6100-3-2 Class C (active input power≤25W) requirement.
VIN
(VAC/Hz)
PIN
(W)
IIN
(mA)
THD
(%)
VIN
(VAC/Hz)
PIN
(W)
IIN
(mA)
THD
(%)
115/60
20.52
179.61
230/50
20.42
93.44
Harmonic
Order
Limit
(mA)
Content
(mA)
Harmonic
Order
Limit
(mA)
Content
(mA)
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
139.54
77.98
41.04
20.52
14.36
12.15
10.53
9.29
8.32
7.52
6.87
6.32
5.85
5.45
5.10
4.79
4.51
4.27
4.05
16.21
2.47
1.07
1.40
1.39
1.33
1.20
1.07
1.03
0.87
0.80
0.69
0.59
0.47
0.37
0.36
0.29
0.25
0.16
9.36
Test
Result
(Pass/Fail)
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
69.43
38.80
20.42
10.21
7.15
6.05
5.24
4.62
4.14
3.74
3.42
3.14
2.91
2.71
2.54
2.38
2.25
2.12
2.02
14.83
3.68
1.65
1.29
1.08
1.09
0.89
0.85
0.79
0.76
0.64
0.54
0.55
0.47
0.40
0.33
0.31
0.24
0.26
16.65
Test
Result
(Pass/Fail)
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
9
EV4026-J-00B– 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
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
10
EV4026-J-00B– EVB DESCRIPTION
EVB TEST RESULTS
Performance waveforms are tested on the evaluation board.
12 LEDs in series, ILED=500mA, VOUT=40V, LP=950μH, NP:NS:NAUX =81:27:17.
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
11
EV4026-J-00B– EVB DESCRIPTION
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
12 LEDs in series, VIN=120VAC/60Hz, ILED=500mA, VOUT=40V, LP=950μH, Np:NS:NAUX =81:27:17.
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
12
EV4026-J-00B– EVB DESCRIPTION
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
12 LEDs in series, VIN=230VAC/50Hz, ILED=500mA, VOUT=40V, LP=950μH, Np:NS:NAUX =81:27:17.
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
13
EV4026-J-00B– 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.
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.
EV4026-J-00B Rev.1.0
www.MonolithicPower.com
9/9/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
14
Similar pages