EV44010-S+HR1000A-S-01C 90W LED Driver Evaluation Board Evaluation Board Report 90W LED Driver Evaluation Board with PFC Design Specs Input Voltage Output Voltage Output Current Output Power Isolation Value 100-305 30-45 2.1 90 Unit VAC VDC A W Yes MP44010HS, HR1000AGS, MP26085DJ,MP100GS AC-DC LED Driver AC-DC Constant Current Power Supply MPS IC Application Document Number EBXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary EV44010-S+HR1000A-S-01C evaluation board provides a reference design for a universal offline isolated LED power supply with 30-45V output, constant 2.1A, which also integrates PFC function. This evaluation board 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 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD FEATURES DESCRIPTION The EV44010-S+HR1000A-S-01C is an evaluation board of MP44010, HR1000A, MP26085 and MP100 for 90W LED driver application. MP44010 is a boundary conduction mode PFC controller which can provide simple and high performance active power factor correction with minimum external components. HR1000A is a controller specific for the resonant half-bridge topology with two channels of 50% complementary duty cycle outputs driving signals. MP26085 is a voltage and current control IC integrated a precision voltage reference and a current source, which is suitable for battery charger, second controller of switching regulator systems, and other types of application required an accurate voltage and current control systems. Ultra Wide Operating Input Range(from 100VAC to 305VAC) High efficiency up to 91% Meet Class C Standard of IEC61000-3-2 Meet EN55015 Standard High Power Factor Short Circuit Protection (Hiccup Mode) Over Voltage Protection 0-10V Dimming 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. MP100 is a compact, inductor-less, goodefficiency, off-line regulator. It steps down the AC line voltage to an adjustable DC output. It is a simple solution to provide a bias voltage to ICs in off-line applications. The EV44010-S+HR1000A-S-01C provides up to 90W output power and operates with ultra wide input range from 100VAC to 305VAC. Besides, the EV44010-S+HR1000A-S-01C has output fault protections, such as short circuit protection, over voltage protection. It also can meet the Class C standard of IEC61000-3-2 and EN55015 standard. ELECTRICAL SPECIFICATIONS Parameter Input AC Voltage Output Current Output Voltage Output Power Symbol Value Units VAC IOUT VOUT POUT 100 to 305 2.1 30 to 45 90 V A V W EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 2 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EV44010-S+HR1000A-S-01C EVALUATION BOARD (L x W x H) (16.2cm x 3.8cm x 2.5cm) Board Number MPS IC Number MP44010HS EV44010-S+HR1000A-S-00C HR1000AGS MP26085DJ MP100GS EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 3 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EVALUATION BOARD SCHEMATIC PFC Stage EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 4 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD LLC Stage EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 5 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EV44010-S+HR1000A-S-01C BILL OF MATERIALS Qty Ref 2 CY1,CY2 1 C1 1 2 C2 C3,C4 1 2 1 1 1 1 1 3 1 1 0 2 1 2 1 Value Description 1nF Y Capacitor;2600V;20% Electrolytic 100μF Capacitor;35V 0.22μF X-CAP;305V 0.47μF Capacitor;450V;CBB Ceramic C5 22nF Capacitor;630V;X7R Ceramic C6,C30 470pF Capacitor;50V;C0G Ceramic C7 10nF Capacitor;630V;X7R Ceramic C8 4.7μF Capacitor;50V;X7R Electrolytic C10 47μF Capacitor;500V Ceramic C13 0.47μF Capacitor;50V;X7R Ceramic C14 2.2μF Capacitor;25V;X7R Ceramic C15,C41,C52 1μF Capacitor;25V;X7R Ceramic C16 15pF Capacitor;50V;X7R Ceramic C17 4.7nF Capacitor;50V;X7R C18,C19,C20, C21,C24,C34, NS C38,C45,C47, C51 Electrolytic C22,C23 330μF Capacitor;63V Ceramic C25 2.2μF Capacitor;100V;X7R Ceramic C26,C42 0.47μF Capacitor;25V;X7R Ceramic C27 0.47μF Capacitor;25V;X7R 1 C28 10nF 2 C29,C35 1μF 1 C31 4.7μF 1 C32 2.2nF Capacitor;1000V Ceramic Capacitor;25V;X7R Ceramic Capacitor;25V;X5R Capacitor;4000V;20% Package Manufacturer Part Number DIP Panasonic JYK08F102ML72N DIP SANYO DIP DIP EPCOS CARLI 1206 TDK 0603 Murata 1206 TDK 1206 Murata DIP Rubycon 0805 Murata 0805 TDK 0603 Murata 0603 TDK 0603 Murata DIP JiangHai 1210 Murata GRM32ER72A225KA35L 0603 Murata GRM188R71E474KA12 0805 HHEC C0805X474K025T DIP FaLa MMKP82-1000V103P15JA 0805 Murata GRM21BR71E105KA99L 0805 Murata GRM21BR61E475KA88 DIP HongKe JN12E222MY02N B32922C322M TF474K2Y10BL270D9R C3216X7R2J223K GRM1885C1H471JA01 C3216X7R2J103K GRM188R71H475KA01D 500BXC47M GRM21BR71H474KA01L C2012X7R1E225K GRM188R71E105KA01D C1608X7R1H150K GRM188R71H472KA01D CD286-63V330 EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 6 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EV44010-S+HR1000A-S-01C BILL OF MATERIALS (continued) Qty Ref Value 4 C33,C36,C39, C44 10nF 1 C37 33nF 1 C40 220pF 3 C43,C48,C49 100μF 1 C46 1nF 1 C50 0.1μF 6 1 R1,R2,R3,R8, R13,R19 R4 Description Ceramic Capacitor;50V;X7R Ceramic Capacitor;25V;X7R Ceramic Capacitor;1000V; Electrolytic Capacitor;25V Ceramic Capacitor;50V;X7R Ceramic Capacitor;100V;X7R Package Manufacturer Part Number 0603 Murata GRM188R71H103KA01D 0805 LION 0805B333K250T 1206 TDK C3216C0G3A221J DIP Rubycon 0603 LION 0603B102K500T 1206 TDK C3216X7R2A104K 25YXF100M 374k Film Resistor;1%; 1206 Yageo RC1206FR-07374KL 107k Film Resistor;1%; 0603 Yageo RC0603FR-07107KL 10k Film Resistor;1%; 0603 Yageo RC0603FR-0710KL 4.7k Film Resistor;1% 0603 Yageo RC0603FR-074K7L 1M Film Resistor;1%; 1206 Yageo RC1206FR-071ML 1 R5,R28,R41, R46,R56,R59, R35,R44 R7 R9,R14,R18, R29,R30,R31 R15 68k Film Resistor;1%; 0805 Yageo RC0805FR-0768KL 1 1 3 1 1 3 R21 R22 R23,R34,R42 R24 R25 R26,R27,R64 6.34k 6.04k 10 7.15k 0 0.5 Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; Film Resistor;5%; Film Resistor;1%; 0603 0603 0805 0603 0603 1206 Yageo Yageo Yageo Yageo Yageo Yageo RC0603JR-076K34L RC0603FR-076K04L RC0805FR-0710RL RC0603FR-077K15L RC0603JR-070RL RC1206FR-070R5L 8 1 6 1 R32,R33,R63, R67,R68,R69, JP1 R36 820k Film Resistor;1%; 0603 Yageo RC0603FR-07820KL 2 1 1 1 1 2 1 R37,R62 R38 R39 R40 R43 R45,R53 R47 2k 3.01k 10.7k 1.74k 499 0 0.05 Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; Film Resistor;5%; Resistor;1%;2W 1206 0603 0603 0603 0603 1206 2512 Yageo Yageo Yageo Yageo Yageo Yageo Yageo RC1206FR-072KL RC0603FR-073K01L RC0603FR-0710K7L RC0603FR-071K74L RC0603FR-07499RL RC1206JR-070RL RL2512FK-070R05L 1 2 1 1 R48 R49,R57 R50 R51 2.49k 360k 100 100 Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; 0805 0603 0603 1206 Yageo Yageo Yageo Yageo RC0805FR-072K49L RC0603FR-07360KL RC0603FR-07100RL RC1206FR-07100RL 0 NS EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 7 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EV44010-S+HR1000A-S-01C BILL OF MATERIALS (continued) Qty Ref Value Description 1 R52 75 Film Resistor;1%; 0603 Yageo RC0603FR-0775RL 1 2 1 1 1 1 R54 R55,R66 R58 R60 R61 R65 1k 20.5k 3.92k 84.5k 24.9k 44.2k Film Resistor;1%; Film Resistor;1%; Film Resistor;1%; Film Resistor;1% Film Resistor;1% Film Resistor;1%; 0603 0603 0603 0603 0603 0603 Yageo Yageo Yageo Yageo Yageo Yageo RC1206FR-071KL RC0603FR-0720K5L RC0603FR-073K92L RC0603FR-0784K5L RC0603FR-0724K9L RC0603FR-0744K2L 1 1 RT1 VAR1 5 471KD14 Resistor MOV DIP DIP 1 BD1 MB6S 1 BR1 GBU406 3 1 D1,D8,D11 D2 RS1J STTH3R06S 1 D3 BZT52C16 1 D13 B160 9 D4,D6,D7, D10,D12,D14, D15,D17,D18 1N4148W 1 D9 1 D16 1 F1 1 L1 900μH 1 L2 350μH 1 L3 24mH 1 L4 410μH 1 L5 250μH 1 L6 47μH Diode;600V;0.5A; BRIDGE RECTIFIER/DF02S;6 00V;4A Diode;600V;1A; Diode;600V;3A; Zener Diode;16V;5mA Schottky Diode;60V;1A; Package SOIC-4 Manufacturer Part Number Semitec 5D2-10 Thinking TVR14471KS42Y TaiWan MB6S Semiconductor DIP Diodes GBU406 SMA SMC Diodes ST RS1J STTH3R06S SOD-123 Diodes BZT52C16 SMA Diodes B160 Diode;75V;0.15A; SOD-123 Diodes 1N4148W MBR20150 Diode;150V;20A TO220AB MCC BZT52C20 Zener Diode;20V;5mA SOD-123 Diodes DIP COOPER BUSSMANN 3.15A/300VAC FUSE-SS-5 Common Choke,900μH,2A Filter Inductor;350μH Common Choke,24mH,2A PFC Inductor, L=410μH, N1:N2=47:8,RM10 Resonant Inductor,L=250μH,R M6 Common Choke,47μH,2.5A MBR20150FCT BZT52C20-F SS-5-3.15A DIP DIP DIP DIP Emei FX0270 DIP Emei FX0269 DIP Wurth 744841247 EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 8 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EV44010-S+HR1000A-S-01C BILL OF MATERIALS (continued) Qty Ref Value Description Package Manufacturer Part Number 1 Q1 S8050 Transistor;25V;0.5A SOT-23 Changjiang Electronics 3 Q4,Q5,Q6 IPP60R199CP TO220 Infineon 1 T1 1mH DIP Emei FX0271 1 1 U1 U2 MP44010 HR1000A SOIC8 SOIC16 MPS MPS MP44010HS HR1000AGS 1 U3 PC817A Photocoupler;1Channel DIP SHARP 1 U4 MP26085 voltage and current controller SOIC8 MPS 1 U5 CJ431 Vref=2.5V SOT-23 Changjiang Electronics 1 U6 0-10V DIMMING,GN D,LED+,LED,L, N MP100 MP100 SOIC8 MPS 6 N-Channel Mosfet;650V;16A Transformer,Lp=1mH N1:N2:N3:N4:N5=39: 7:7:3:3, BPQ26-20 PFC controller LLC controller S8050 IPP60R199CP PC817A MP26085DJ CJ431 MP100GS Connector EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 9 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VAC=100V to 305V, IOUT=2.1A, POUT=90W EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 10 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VAC=100V to 305V, IOUT=2.1A, POUT=90W EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 11 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VAC=100V to 305V, IOUT=2.1A, POUT=90W EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 12 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD PRINTED CIRCUIT BOARD LAYOUT Figure 1—Top Layer Figure 2—Bottom Layer EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 13 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD QUICK START GUIDE 1. Preset AC input voltage between 100V and 305V. Then turn off AC power supply. 2. Connect the output pins, LED+ & LED- to the LEDs. 3. Connect the Line and Neutral terminals of the power supply output to AC input pins, L & N. 4. Turn on the power supply. The board will start up automatically. 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. EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 14 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD APPENDIX1: PFC INDUCTOR SPECIFICATION Electrical Diagram Winding Diagram Tapes:3T 1,2 N2 4 N1 Tapes:1T N2 11,12 9 N1 Winding Start TEFLON TUBE Pri Aux copper1 Pin Definition of Bobbin 8mm copper2 Pin out 1 2 12 3 8mm 11 10 Note: use copper wires to connect copper1 & copper2 with pin 9 of bobbin. 4 5 9 8 6 7 View from the top Table 1—Electrical Characteristic Parameter Primary Inductance Condition Value L（1—12） 410μH±5% Core RM10 Bobbin RM10 Core Material DMR40 or equivalent Turn Ratio N1:N2 47:8 Table 2—Winding Specification Tape Turns Winding No. Start& End Wire Diameter (mm) Turns 1 N1 1&2→11&12 0.33×5 47 3 N2 9→4 0.2×1 8 Margin Tapes EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 15 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD APPENDIX2: LLC TRANSFORMER SPECIFICATION Electrical Diagram Winding Diagram 3mm 11 N3 4 3mm Tapes:3T N5 9 8 N1 5 Tapes:1T N4 Tapes:1T N4 1 N3 10 7 N2 2 Tapes:3T N2 Tapes:1T N5 N1 9 Pri Winding Start Teflon Tube Sec Pin Definition of Bobbin 8mm copper 8mm Note: use a copper wire to connect copper with pin 2 of bobbin. Table 1—Electrical Characteristic Parameter Primary Inductance Condition Value L(4-5) 1mH±5% Core PQ26-20 Bobbin PQ26-20 DMR40 or equivalent Core Material Turn Ratio N1:N2:N3:N4:N5 39:3:7:7:3 Table 2—Winding Specification Tape Turns 1 3 1 1 Winding No. N1 N2 N3 N4 3 N5 3mm 3mm 3mm 3mm Start& End 4→5 1→2 11→9 8→10 Wire Diameter (mm) 0.25×2 0.2×8 0.33×4 0.33×4 3mm 7→9 0.2×1 Margin Tapes Turns 39 3 7 7 3 EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 16 EV44010-S+HR1000A-S-01C –90W LED DRIVER EVALUATION BOARD APPENDIX3: LLC RESONANT INDUTOR SPECIFICATION Electrical Diagram Winding Diagram 2 Tapes:3T N1 6 N1 Winding Start TEFLON TUBE Table 1—Electrical Characteristic Parameter Primary Inductance Pri Pin Definition of Bobbin Pin out 1 2 6 Condition Value L(2-6) 250μH±5% Core RM6 Bobbin RM6 Core Material DMR40 or equivalent Turn Ratio N1 43 3 5 4 View from the top Table 2—Winding Specification Tape Turns 3 Winding No. N1 Margin Tapes Start& End 2→6 Wire Diameter (mm) 0.27×3 Turns 43 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. EV44010-S+HR1000A-S-00C Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 17