EB1201

EV44010HS+4688DN-00A
BOUNDARY MODE PFC CONTROLLER
EVALUATION BOARD
Evaluation Board Report
30W AC-DC LED Lighting Driver with PFC
Design Specs
Input Voltage
Output Current
Output Power
Isolation
MPS IC
Value
85-265
350
30
Unit
VAC
mA/channel
W
Yes
MP44010HS, MP4688DN
AC-DC LED lighting
AC-DC Constant Current Power Supply
Application
Document Number
EBXXX
Author
Application Engineering Department
Date
Nov, 2014
Revision
1.0
Design Summary
EV44010HS+4688DN-00A evaluation board provides a reference design for a universal offline isolated
LED power supply that can provide two channel outputs, each channel can provide 350mA/15W to
drive LEDs. For this design the MP44010HS is used as flyback and PFC controller, and two
MP4688DNs are used to regulate constant current output for each channel.
The design contains the complete specification of the power supply, a detailed circuit diagram, the
entire bill of materials required to build the power supply, drawing of the power inductors and
transformers, and test data of the most important performance.
EV44010-S+HR1000-S-01B Rev. 1.0
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
1
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
DESCRIPTION
ELECTRICAL SPECIFICATIONS
The EV44010HS+4688DN-00A is an evaluation
board of MP44010 and MP4688 for 30W LED
lighting driver.
Parameter
The EV44010HS+4688DN-00A contains 2
stages: the first stage is flyback PFC using
MP44010 which can provide high power factor;
the second stage is 2-channel DC/DC using
MP4688 and every channel can deliver
15W/350mA for LED.
MP44010 is a boundary conduction mode PFC
controller which can provide simple and high
performance active power factor correction
using minimum external components.
MP4688 is a high voltage input step-down
switching regulator to deliver a constant current
to LED. The hysteresis current mode control is
applied to reach very fast response.
The EV44010HS+4688DN-00A can meet the
Class C standard of IEC61000-3-2 and
EN55015 standard.
Symbol
Value
Units
Input AC Voltage
VAC
85 to 265
VAC
Output current
/ Channel
IOUT
350
mA
Output Power
POUT
30
W
FEATURES









Wide Operating Input Range(from 85V to
265VAC)
Meet Class C Standard of IEC61000-3-2
Meet EN55015 Standard
Boundary Conduction Mode for PFC Stage
Hysteresis Current Mode Control for DC/DC
Stage
±5% LED Current Accuracy
Up to 20kHz PWM Dimming Frequency
Dedicated PWM Dimming Control Input
Output Short Circuit Protection
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.
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
2
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
EV44010HS+4688DN-00A EVALUATION BOARD
(L x W x H) (15cm x 3cm x 2.78cm)
Board Number
EV44010HS+4688DN-00A
MPS IC Number
MP44010HS
MP4688DN
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
3
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
EVALUATION BOARD SCHEMATIC
R27
280kΩ
C7 4.7nF
D5
R23
UF3004
0Ω
T1
R5
499kΩ
1mH
R6
D2
20Ω
1N4148
BR1
0.22μF
R3
C8
10nF N1
N2
PC817
N3
N4
2.2nF
R9
Lcm1
32mH
C4
220nF
CX1
C3
22μF
C2
R4
13.3kΩ
D1
BZT52C18
R8
30.1kΩ
R10
10kΩ
R7
1.24kΩ
10kΩ
FB
0.1μF
VAR1
COMP
GATE
MULT
GND
CS
F1
U2
5.1Ω
5.1Ω
R16
R11
C5
NS
R17
0.2Ω
D10
B190
280kΩ
LED2-
GND
N/C
C19
10kΩ
2.2μF
10kΩ
SW
MP4688
C23
0.1μF
EN2
R34
DIM
NS
0Ω
LED2+
C21 15nF
EN
VIN
U5
C22
NS
0.56Ω
FB
C13
2.2μF
L1
1mH
0.1μF
R32
C20
2.2μF
0.2Ω
NS
0.1μF
BST
R22
R30
R33
R21
U3
CJ431
SW
R31
R20
2.37kΩ
Q1
FQPF8N80C
BST
C25
0Ω
PC817
DIM
LED1+
EN1
EN
VIN
C16
C18
NS
C17 15nF
U4 MP4688
C15
2.2μF
R26
U1
ZCS
2.2μF
1kΩ
1kΩ
MP44010
AC Input
R19
1N4148
R15
R25
300Ω
D7
BZT52C10
VIN
R14
C14
Q2
S8050
R18
499Ω
GND
N/C
R24
249kΩ
10kΩ
0.56Ω
FB
C12
22μF
C11
22μF
1N4148
R12
68kΩ
D3
C10
22μF
D6
FB1
742792141
C6
0.1μF
R28
D9
BZT52C30
FR107
D4
R2
NS
R1
NS
D8
BZT52C30
330uF
C9
2MΩ
C1
220nF
CX2
R13
300kΩ
LED1-
0.1μF
R29
GBU406
Ldm1
C24
L2
1mH
D11
B190
EV44010HS+4688DN-00A BILL OF MATERIALS
Qty
1
1
1
1
0
Ref
Value Description
Package
Manufacturer Part Number
C1
0.22μF CBB Cap.,630V
C2
2.2nF Ceramic Cap., 50V, X7R
C3
22μF Electrolytic Cap., 50V
C4
220nF Ceramic Cap., 16V, X7R
C5, C18, C22
NS
C6,C16,C23,
0.1μF Ceramic Cap., 50V, X7R
C24,C25
C7
4.7nF Y Cap., 2600V
DIP
0603
DIP
0603
Panasonic
Murata
JiangHai
Murata
ECQE6224KF
GRM188R71H222KA01D
CD281L-50V22
GRM188R71C224KA93D
0603
Murata
GRM188R71H104KA93D
DIP
HongKe
JYK12F472MY72N
Ceramic Cap., 630V, X7R
Electrolytic Cap., 100V
Ceramic Cap., 25V, X5R
Ceramic Cap., 16V, X5R
1206
DIP
1210
0805
TDK
JiangHai
Murata
Murata
C3216X7R2J103K
CD263-100V330
GRM32ER61E226KE15L
GRM21BR61C225KA88L
2.2μF Ceramic Cap., 100V, X7R
1210
Murata
GRM32ER72A225KA35L
2
1
C8
C9
C10, C11, C12
C13
C14, 15,
C19, C20
C17,C21
CX1
15nF Ceramic Cap., 50V, X7R
0.1μF X Cap.,275V
0603
DIP
TDK
KaiLi
C1608X7R1H153K
PX104K3ID19L270D9R
1
1
3
1
1
CX2
D1
D2, D3, D6
D4
D5
DIP
SOD-123
SOD-123
DIP
DIP
KaiLi
Diodes
Diodes
Diodes
Diodes
PX224K3ID49L270D9R
BZT52C18
1N4148W
FR107
UF3004
5
1
1
1
3
1
4
10nF
330μF
22μF
2.2μF
0.22μF X Cap.,275V
Diode, 5mA, 18V
Diode, 0.15A, 75V
Diode, 1A, 1000V
Diode, 3A, 400V
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
4
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
EV44010HS+4688DN-00A BILL OF MATERIALS (continued)
Qty
Ref
Value
Description
Package
Manufacturer Part Number
1
D7
Diode, 5mA, 10V
SOD-123
Diodes
BZT52C10
2
2
1
3
1
1
D8, D9
D10, D11
BR1
L1, L2, Ldm1
Lcm1
VAR1
Diode, 2mA, 30V
Diode, 1A, 90V
Diode, 600V, 4A
SOD-123
SMA
DIP
DIP
DIP
DIP
Diodes
Diodes
Diodes
BZT52C30
B190A
GBU406
Jingdian
0
R1, R2,
R30, R34
NS
1
1
1
1
1
1
R3
R4
R5
R6
R11
R7
2MΩ
13.3kΩ
499kΩ
20Ω
0Ω
1.24kΩ
Film Res., 5%
Film Res., 1%
Film Res., 1%
Film Res., 5%
Film Res., 5%
Film Res., 1%
DIP
0603
1206
1206
1206
0603
Any
Yageo
Panasonic
Royalohm
Yageo
Yageo
RC0603FR-0713K3L
ERJ8ENF4993V
1206J0200T5E
RC1206JR-070RL
RC0603FR-071K24L
1
30.1kΩ Film Res., 1%
0603
Yageo
RC0603FR-0730K1L
1
R9
R8, R10,
R22, R29,
R33
R12
1
2
2
1
2
1
R13
R14, R15
R16, R17
R18
R19, R21
R20
2
1
1
2
2
1
R23, R26
R24
R25
R27, R31
R28, R32
FB1
1
1
Q1
Q2
1
F1
1
1
1
1
2
T1
U1
U2
U3
U4, U5
5
1mH
32mH
470V
TVR14471KS42Y
10kΩ
Film Res., 1%
0603
Yageo
RC0603FR-0710KL
68kΩ
Film Res., 1%
0603
Yageo
RC0603FR-0768KL
300kΩ
5.1Ω
0.2Ω
499Ω
1kΩ
2.37kΩ
Film Res., 1%, 1W
Film Res., 5%
Film Res., 1%
Film Res., 1%
Film Res., 1%
Film Res., 1%
DIP
1206
0805
0603
0603
0603
Any
Yageo
RC1206JR-075R1L
Yange
Royalohm
Yageo
RC0603FR-07499RL
0603F1001T5E
RC0603FR-072K37L
0Ω
249kΩ
300Ω
280kΩ
0.56Ω
Film Res., 5%
Film Res., 1%
Film Res., 1%
Film Res., 1%
Film Res., 1%
Magnetic Bead
0603
0603
0603
0603
0805
1206
Royalohm
Yageo
Yageo
Yageo
Yageo
Wurth
0603J0000T5E
RC0603FR-07249KL
RC0603FR-07300RL
RC0603FR-07280KL
RL0805FR-070R56L
742792141
MOSFET, 8A, 800V
Transistor, 0.5V, 25V
1A
250V
EF25, 100:33:8:9
Photocoupler
BCM PFC Controller
2.5V
Step-Down Regulator
TO-220
SOT-23
DIP
SMD
SO-8
SOT-23
SO-8
FQPF8N80C
S8050
COOPER
Bussmann
Sharp
MPS
Changdian
MPS
SS-5-1A
FX0148
PC817B
MP44010HS
CJ431
MP4688DN
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
5
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
EVB TEST RESULTS
Performance waveforms are tested on the evaluation board.
VAC=85V to 265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.15mH,
N1:N2:N3:N4=100:33:8:9.
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
6
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
VAC=85V to 265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.15mH,
N1:N2:N3:N4=100:33:8:9.
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
7
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
VAC=85V to 265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.15mH,
N1:N2:N3:N4=100:33:8:9.
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
8
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
PRINTED CIRCUIT BOARD LAYOUT
Figure 1—Top Silk Layer
Figure 2—Bottom Silk Layer
Figure 3—Bottom Layer
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
9
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
QUICK START GUIDE
1. Preset AC input voltage between 85V and 265V. Then turn off AC power supply.
2. Connect the LED string to the LED+ and LED- pins on each channel.
3. Connect the Line and Neutral terminals of the power supply output to AC input.
4. Turn the power supply on. The board will automatically startup.
Contact Information
To request this evaluation board, please refer to your local sales offices which can be found from:
http://www.monolithicpower.com/Company/Contact-Us
Disclaimer
Monolithic Power Systems (MPS) reserves the right to make changes to its products and to discontinue
products without notice. The applications information, schematic diagrams, and other reference
information included herein is provided as a design aid only and are therefore provided as-is. MPS
makes no warranties with respect to this information and disclaims any implied warranties of
merchantability or non-infringement of third-party intellectual property rights.
MPS cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a
MPS product. No circuit patent licenses are implied.
Certain applications using semiconductor products may involve potential risks of death, personal injury,
or severe property or environmental damage (“Critical Applications”).
MPS PRODUCTS ARE NOT DESIGNED, INTENDED, AUTHORIZED, OR WARRANTED TO BE
SUITABLE FOR USE IN LIFE‑SUPPORT APPLICATIONS, DEVICES OR SYSTEMS, OR OTHER
CRITICALAPPLICATIONS.
Inclusion of MPS products in critical applications is understood to be fully at the risk of the customer.
Questions concerning potential risk applications should be directed to MPS.
MPS semiconductors are typically used in power supplies in which high voltages are present during
operation. High voltage safety precautions should be observed in design and operation to minimize the
chance of injury.
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
10
EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD
APPENDIX: TRANSFORMER SPECIFICATION
Electrical Diagram
Primary Winding
Winding Diagram
Secondary Winding
Margin Tapes
1
Margin Tapes
10
N1
Tapes:3T
N2
NS
N5
8
N5
Tapes:3T
8
4
3
N4
N3
Tapes:1T
6
N4
Auxiliary Winding
5
N3
Winding Start
Teflon Tube
Auxiliary Winding
Tapes:1T
N2
Pin Definition of Bobbin
Tapes:3T
Pin out
N1
1
10
2
9
Tapes:1T
Table 1. Electrical Characteristic
3
8
Parameter
Primary
Inductance
4
7
Core
EF25
Bobbin
EF25
Core Material
3C85 or
equivalent
5
6
Turn Ratio
View from the top
Condition
Value
Lp(4-1)
1.15mH±5%
N1:N2:N3:N4:N5
50:33:8:9:50
Table 2. Winding Specification
Tape
Turns
3
1
1
1
3
Winding
No.
N1
N2
N3
N4
N5
Margin Tapes
2mm
2mm
2mm
2mm
2mm
Start&
End
4→NS
10→8
6→8
3→5
NS→1
Wire Diameter
(mm)
0.33×1
0.33×2
0.18×1
0.18×1
0.33×1
Turns
50
33
8
9
50
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.
EV44010HS+4688DN-00A Rev. 1.1
www.MonolithicPower.com
10/16/2015
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2015 MPS. All Rights Reserved.
11
Similar pages