EV44010-S+HR1000A-S-00A 150W Street Light Evaluation Board Evaluation Board Report 150W Street Light Evaluation Board with PFC Design Specs Input Voltage Output Voltage Output Power Isolation MPS IC Value 85-305 70 150 Unit VAC VDC W Yes MP44010HS, HR1000HS AC-DC LED Driver AC-DC Constant Current Power Supply Application Document Number EBXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary EV44010-S+HR1000A-S-00A evaluation board provides a reference design for a street light LED power supply with 70V output at 150W maximum, 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 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 1 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD DESCRIPTION FEATURES The EV44010-S+HR1000-S-00A is a general purpose evaluation board of MP44010 and HR1000 for 150W street lamp application. MP44010 is a boundary conduction mode PFC controller which can provide simple and high performance active power factor correction with minimum external components. HR1000 is a controller specific for the resonant half-bridge topology with two channels of 50% complementary duty cycle outputs driving signals. The EV44010-S+HR1000-S-00A provides up to 150W output power and operates with ultra wide input range from 85V to 305V. Besides, the EV44010-S+HR1000-S-00A 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 Symbol Value Units Input AC Voltage Output Voltage VAC VOUT 85 to 305 70 V V Output Power POUT 150 W Ultra Wide Operating Input Range(from 85V to 305V) High efficiency up to 92% Meet Class C Standard of IEC61000-3-2 Meet EN55015 Standard High Power Factor Short Circuit Protection (Latch) Over Voltage Protection APPLICATIONS LED Street Lamp Application LCD TV&ATX Power Supply High Power & Efficiency Adaptor Telecom Power Supply 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. EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 2 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EV44010-S+HR1000-S-00A EVALUATION BOARD (L x W x H) (13.6cm x 9.0cm x 3.8cm) Board Number MPS IC Number EV44010-S+HR1000-S-00A MP44010HS HR1000HS EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 3 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EVALUATION BOARD SCHEMATIC PFC Stage EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 4 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD LLC Stage EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 5 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EV44010-S+HR1000-S-00A BILL OF MATERIALS Qty 2 Ref 1206 TDK C3216X7R2J223K DIP Hongke JYK08F102ML72N DIP EPCOS B32922C3474K C8 0.68μF CBB Cap., 630V C9,C22,C25 10nF Ceramic Cap., 50V; X7R C33,C38 C10 2.2nF Ceramic Cap., 50V; X7R C11 22μF Ceramic Cap., 25V; X5R C12, C17 0.1μF Ceramic Cap., 50V; X7R C13 0.47μF Ceramic Cap;16V;X7R C14,C28,C36 1μF Ceramic Cap., 50V; X7R DIP Panasonic ECQE6684KFB 0603 muRata GRM188R71H103KA01D 0805 1206 0603 0805 0805 muRata muRata TDK muRata muRata GRM216R71H222KA01D GRM31CR61E226KE15 C1608X7R1H104K GRM219R71C474KA01 GRM21BR71H105KA12L Electrolytic Cap., 250V Ceramic Cap., 25V; X5R Ceramic Cap;25V;X7R Ceramic Cap., 50V; X7R Ceramic Cap;50V;X7R Ceramic Cap;25V;X7R Ceramic Cap;1000V;X7R DIP 0805 0603 0805 0603 0805 1206 Jianghai muRata muRata TDK muRata muRata muRata CD11G-250V220 GRM21BR61E475KA12 GRM188R71E474KA12 C2012X7R1H103K GRM188R71H471KA01D GRM21BR71E334KA01L GRM31A7U3A221JW31D 1 1 1 3 1 1 C30 22nF Film Cap., 1000V C31 220μF Electrolytic Cap., 25V C32 3.3nF Y Cap., 4000V C39, C40,C42 100μF Electrolytic Cap., 100V C41 2.2μF Ceramic Cap., 100V; X7R C43 0.1μF Ceramic Cap., 630V; X7R DIP DIP DIP DIP 1210 1812 Fala Jianghai Hongke Jianghai TDK muRata MMKP82-1000V-223P15 CD287-25V220 JNK14E332MY04N CD287-100V100 C3225X7R2A225K GRM43DR72J104KW01 1 C44 R1,R2,R3,R25 ,R26 R4 R46,R47,JR7, JR8 R5,R6,R7,R9, R10,R36,R37, R39,R52 10nF Ceramic Cap., 630V; X7R 1206 muRata GRM31BR72J103KW01 374k Film Resistor, 1% 1206 Yageo RC1206FR-07374KL 158k Film Resistor, 1% 0805 Yageo RC0805FR-07158KL 1M Film Resistor, 1% 1206 Yageo RC1206FR-071ML R8 R11 R12, R49 R13 20k 6.04k 100k 5.6k Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% Film Resistor, 5% 0603 0603 0603 0603 Yageo Yageo Yageo Yageo RC0603FR-0720KL RC0603FR-076K04L RC0603FR-07100KL RC0603JR-075K6L 0 2 1 5 1 1 2 1 3 2 1 2 1 1 1 1 5 1 0 9 1 1 2 1 C18, C19 C20 C21,C26 C23 C24 C27 C29 22nF 220μF 4.7μF 0.47μF 10nF 470pF 0.33μF 220pF Ceramic Cap., 630V, X7R Package Manufacturer Part Number C2, C6 1nF Y Cap., 2600V C3,C15,C16, C34,C35,C37, NS C45,C46,C47, C48 C4,C5 0.47μF X cap., 305V AC 2 C1,C7 Value Description NS EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 6 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EV44010-S+HR1000-S-00A BILL OF MATERIALS (continued) Qty Ref Value 2 R14, R51 4.7k Film Resistor, 5% 0603 Yageo RC0603JR-074K7L 1 3 2 R17 R18,R41, R42 R19, R20 R21,R22,R23, R24 R27 R28 R29 68k 10 0.3 Film Resistor, 1% Film Resistor, 5% Film Resistor, 1% 0805 1206 1206 Yageo Yageo Yageo RC0805FR-0768KL RC1206JR-0710R RL1206FR-070R3L 2.2M Film Resistor, 1% 1206 Yageo RC1206FR-072M2L 5.1k 3k 9.09k Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% 0603 0603 0603 Yageo Yageo Yageo RC0603FR-075K1L RC0603FR-073KL RC0603FR-079K09L 1.5k 11.5k 820k 10.7k 130 Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% 0603 0603 0603 0603 0603 Yageo Yageo Yageo Yageo Yageo RC0603FR-071K5L RC0603FR-0711K5L RC0603FR-07820KL RC0603FR-0710K7L RC0603FR-07130RL 0 Film Resistor, 5% 0805 Yageo RC0805JR-070RL 1 1 3 R30 R31 R32 R33 R34 R16,R35,JR1, JR2,JR3,JR5, JR6, R38 R40 R43, R44, R48 100 10k 10k Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% 1206 0603 0805 Yageo Yageo Yageo RC1206FR-07100RL RC0603FR-0710KL RC0805FR-0710KL 2 1 1 1 1 1 R45,JR4 R50 R53 R54 R55 R56 0 2.37k 120k 150k 20 10 Film Resistor, 5% Film Resistor;1% Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% Film Resistor, 1% 1206 0603 0603 0603 0603 0805 Yageo Yageo Yageo Yageo Yageo Yageo RC1206JR-070RL RC0603FR-072K37L RC0603FR-07120KL RC0603FR-07150KL RC0603FR-0720RL RC0805FR-0710RL 1 RT1 DIP Xingshun 5D2-10 1 VAR1 DIP Jingdian TVR14471KS42Y 1 BR1 D1,D6,D8,D11, D12 DIP Vishay GBU8J SOD-123 Diodes 1N4148W Diodes BZT52C18 Diodes RS1J Diodes BZT52C16 Diodes MUR860 Diodes BZT52C20 4 1 1 1 1 1 1 1 1 7 5 1 D2 3 D3,D5,D7 1 D4 1 D9 2 0 D10, D17 D13,D14 Description 5 NTC Resistor TVR14471 MOV,470V KS42Y GBU8J Diode, 600V, 8A 1N4148 Diode, 75V, 0.15A Package Zener Diode, 18V, SOD-123 5mA RS1J Diode, 600V, 1A SMA Zener Diode, 16V, BZT52C16 SOD-123 5mA Schottky Diode, 600V, MUR860 TO-220 8A BZT52C20 Zener Diode, 20V SOD-123 NS BZT52C18 Manufacturer Part Number EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 7 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EV44010-S+HR1000-S-00A BILL OF MATERIALS (continued) Qty Ref Value 1 D15 B160 1 D16 MBR20H200CT 1 D18 BZT52C30 1 2 3 1 1 0 Q1 Q2, Q3 Q4,Q5,Q6 Q7 F1 L1 AP2761I-A S8050 IPP60R199CP MMBTA06LT1G SS-5H-4A NS 1 L2 350μH 1 L3 33mH 1 L4 280μH 1 L5 120μH 1 L6 42μH 1 T1 625uH 1 1 U1 U2 MP44010 HR1000 1 U3 PC817A 1 U4 TL431K Description Package Manufacturer Part Number Schottky Diode, 60V/1A Diode;200V;20A SMA DIODES TO-220 Vishay MBR20H200CT SOD-123 Diodes BZT52C30 N-Mosfet, 650V,10A Transistor;25V;0.5A; Mosfet, 650V Transistor, 80V, 0.5A Fuse 4A/300V TO-220 SOT-23 TO-220 SOT-23 DIP APEC Changdian Infineon Diodes Cooper Filter Inductor,350μH Common Choke,33mH,4A PFC Inductor, L=280μH, N1:N2=34:5,PQ32 Resonant Inductor,53T L=120μH, EE19 Common Choke,42μH Transformer, Lp=625μH N1:N2:N3:N4=33:3:1 1:11, EC28-34 PFC Controller LLC controller Photocoupler;1Channel Vref=2.5V DIP Zener 2mA Diode, 30V, DIP B160 AP2761I0A-HF-3TB S8050 IPP60R199CP MMBTA06LT1G SS-5H-4A Wurth 744825433 Wurth 744842742 SOIC8 SOIC16 MPS MPS MP44010HS HR1000HS PC817A Yiguang PC817A SOT-23 Changdian TL431K DIP DIP DIP DIP EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 8 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VAC=85V to 305V, VOUT=70V, POUT=150W EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 9 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VAC=85V to 305V, VOUT=70V, POUT=150W EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 10 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VAC=85V to 305V, VOUT=70V, POUT=150W EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 11 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD PRINTED CIRCUIT BOARD LAYOUT Figure 1—Top Silk Layer Figure 2—Bottom Silk Layer Figure 3—Bottom Layer EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 12 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD QUICK START GUIDE 1. Preset AC input voltage between 85V and 305V. Then turn off AC power supply. 2. Connect the output pin, VOUT & GND to the E-load or resistive load. 3. Connect the Line and Neutral terminals of the power supply output to AC input pin, 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+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 13 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD APPENDIX1: PFC INDUCTOR SPECIFICATION Electrical Diagram Winding Diagram 4 3 N1 N2 6 2 Winding Start TEFLON TUBE Primary Winding Auxiliary Winding Pin Definition of Bobbin Pin out Table 1—Electrical Characteristic 1 12 Parameter Primary Inductance Condition Value L（4—6） 280μH±5% 2 11 Core PQ32/20 3 10 Bobbin PQ32/20 4 9 Core Material DMR40 or equivalent 5 8 6 7 Turn Ratio N1:N2 34:5 View from the top Table 2—Winding Specification Tape Turns Winding No. Start& End Wire Diameter (mm) Turns 3 N1 4→6 0.33×7 34 3 N2 2→3 0.2×2 5 Margin Tapes EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 14 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD APPENDIX2: LLC TRANSFORMER SPECIFICATION Electrical Diagram Winding Diagram 3mm Primary Winding 3mm 11 1 N3 N1 9 8 3 5 N2 Tapes:3T N4 Tapes:1T N4 6 10 Winding Start Teflon Tube Auxiliary Winding N3 Tapes:3T Secondary Winding N2 Pin Definition of Bobbin Tapes:1T N1 Table 1—Electrical Characteristic Parameter Primary Inductance Condition Value L(1-3) 0.625mH±5% Core EC28-34 Bobbin EC28-34 Core Material DMR40 or equivalent Turn Ratio N1:N2:N3:N4 33:3:11:11 Table 2—Winding Specification Tape Turns 1 3 1 3 Winding No. N1 N2 N3 N4 Margin Tapes 3mm 3mm 3mm 3mm Start& End 1→3 5→6 11→9 8→10 Wire Diameter (mm) 0.2×8 0.2×2 0.2×15 0.2×15 Turns 33 3 11 11 EV44010-S+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 15 EV44010-S+HR1000-S-00A –150W STREET LAMP EVALUATION BOARD APPENDIX3: LLC RESONANT INDUTOR SPECIFICATION Electrical Diagram Winding Diagram 4 N1 5 Winding Start TEFLON TUBE Table 1—Electrical Characteristic Parameter Primary Inductance Primary Winding Pin Definition of Bobbin Condition Value L(4-5) 120μH±5% Core EE19 Bobbin EE19 Core Material DMR40 or equivalent Turn Ratio N1 53 Table 2—Winding Specification Tape Turns 3 Winding No. N1 Margin Tapes Start& End 4→5 Wire Diameter (mm) 0.2×8 Turns 53 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+HR100-S-00A Rev. 1.0 www.MonolithicPower.com 10/13/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 16