EB1107

EV4026-J-00C
Universal Input, 18W
Primary-side-control with Active PFC
Isolated T8 LED Lamp Driver Evaluation Board
The Future of Analog IC Technology
DESCRIPTION
FEATURES
The EV4026-J-00C 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-00C is typically designed for
driving an isolated 18W T8 LED lamp with
36VTYP, 500mA LED load at universal input
(90V-265VAC, 50/60Hz).
The EV4026-J-00C 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
η
90-264
36
500
18
84~86
VAC
V
mA
W
%
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(OVP)
Short-circuit protection(SCP)
Primary-side over-current protection(OCP)
Over-temperature protection(OTP)
Fit inside T8 tube enclosure
APPLICATIONS
•
•
•
•
T8 Tube Replacement
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-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
1
EV4026-J-00C– EVB DESCRIPTION
EV4026-J-00C EVALUATION BOARD
(L x W x H) 238mm x 18mm x 10mm
Board Number
MPS IC Number
EV4026-J-00C
MP4026GJ-Z
EVALUATION BOARD SCHEMATIC
T1
EDR2609
Lp=740uH
Np:Nsec:Naux=40:10:7
R1
R15
680k/1206
5.1k/1206
1
2
R13
NS
1
C6
10nF/630V/1206
1
2
6
1
2
3
1
4
CX1
100nF/275Vac
1
4
LED+
2
MURS320T3
200V/3A/SMC
3
D3
1N4007
2
2
D4
R16
680k/1206
2
C1
220nF/450V
1
C7
NS
1
L3
2.2mH
R14
30k/1206
C8
330uF/50V
8
BD1
DF06S
C9
330uF/50V
36V/500mA
L4
600uH
LED-
5
R2
300k/1W
R3
499k/1%/1206
L5
Bead/742792063
2
CY1
1
D2
BAV23A/SOT-23
1
1
L2
60mH
2
2.2nF/4000V
3
R7
R6
R5
20/1206
2
845k/1%
L1
1.2mH
1
D1
BZT52C27
2
N
90VAC-264VAC
6
2
MULT
CS/ZCD
R8
20/0805
COMP
GND
C5
10pF/50V
3
C4
1uF/10V
0805
1
Q1
SMK0870F
700V/8A
5
R4
8.2k/1%
1
L
GATE
R9
1k/1%
1
F1
250V/2A
C3
2.2nF/50V
VCC
3
1
TVR10431
4.87k/1%
U1
MP4026
R17
499k/1%/1206
2
2
C10
6.8uF/50V
2
RV1
C2
0.1uF/50V
4
R10
0.5/1%/1206
R11
1.1/1%/1206
R12
1.1/1%/1206
Figure 1 - Schematic
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
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© 2013 MPS. All Rights Reserved.
2
EV4026-J-00C– EVB DESCRIPTION
PCB LAYOUT (DOUBLE-SIDED)
Figure 2 - Top Layer
Figure 3 - Bottom Layer
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
3
EV4026-J-00C– EVB DESCRIPTION
CIRCUIT DESCRIPTION
The EV4026-J-00C 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, L1, L2, L3, R1, CX1, C1 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, R1 and C1 associated with L4, CY1 form the
EMI filter which can meet the requirement for
universal input. The bridge rectifier BD1 rectifies
the input line voltage. Small bulk CBB capacitor
C1 is used for a low impedance path for the
primary switching current, to maintain high power
factor, the capacitance of C1 should be selected
with low value.
R3, R4, R17, C3 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.
R2, R5, C2, C10, D2 are used to supply the
power for MP4026. A 6.8μF electrolytic capacitor
C10 is selected to maintain the supply voltage. At
start-up, C10 is first charged up by the starter
resistor R2 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 R5, D2.
R7, R9, D2, C5 are used to detect the auxiliary
winding to get the transformer magnetizing
current zero crossing signal for realizing the
valley switching operation, and also monitor the
output OVP condition. The OVP voltage is set by
the divider ratio of R7, R9. D2 is used to block
the negative plateau voltage of auxiliary winding
when MOSFET is turn on. C5 is used to
decouple the high frequency noise influence on
CS/ZCD pin.
R10, R11, R12 are primary sensing resistors for
primary side current control. The value of R10,
R11 and R12 set the output LED current. R6 is
used to form a feedforward from input line
voltage to optimize the line regulation. C6, R15,
R16, D3 are used to damp the leakage
inductance energy so the drain voltage can be
suppressed at a safe level.
Diode D4 rectifies the secondary winding voltage
and the capacitor C8, C9 are the output filter.
The resistor R14 is placed as pre-load to limit the
output voltage rise too high in open load
condition.
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
4
EV4026-J-00C– EVB DESCRIPTION
EV4026-J-00C BILL OF MATERIALS
Qty
Ref
Value
Description
Rectifier Bridge, 600V,
1A
Package
Manufacture
Manufacturer_PN
SMD
SEP
DF06S
DIP
Carli
TF224K2Y109L270D9R
0603
Murata
GRM188R71H104KA93D
0603
Murata
GRM188R71H222KA01D
0805
Murata
GRM21BR71A105KA01L
0603
Murata
GRM1885C1H100JA01
1206
Murata
GRM31BR72J103KW01L
DIP
Jianghai
CD263-50V330
DIP
Sancon
CF120302-5
DIP
Carli
PX104K3ID19L270D9R
Hongke
JN12E222MY02N
Diodes
BZT52C27
BAV23A-7
1N4007
MURS320T3
1
BD1
DF06S
1
C1
220nF/450V
1
C2
100nF/50V
1
C3
2.2nF/50V
1
C4
1μF/10V
1
C5
10pF/50V
1
C6
10nF/630V
1
C7
C8,
C9
NS
1
C10
6.8μF/50V
1
CX1
100nF/275V
1
CY1
2.2nF/4000V
Electrolytic Capacitor,
50V
Electrolytic Capacitor,
50V
Film Capacitor, X2,
275V
Y1 Capacitor, 4000V
1
D1
BZT52C27
Zener Diode, 27V
1
1
1
D2
D3
D4
BAV23A
1N4007
MURS320T3
Diode, 0.2A, 200V
Diode, 1A, 1000V
Diode, 3A, 200V
DIP
SOD123
SOT-23
DO-41
SMC
1
F1
250V/2A
Fuse
DIP
1
1
1
1
L1
L2
L3
L4
1.2mH
60mH
2.2mH
600μH
DIP
DIP
DIP
DIP
1
L5
742792063
Common Inductor
Common Inductor
Inductor, 2.2mH, 0.5A
Common Inductor
EMI Suppression
Ferrite Bead
Diodes
Diodes
ON Semi
COOPER
BUSSMANN
Emei
OEMA
OEMA
Emei
0805
Wurth
742792063
1
Q1
SMK0870F
TO220F-3L
AUK
SMK0870F
1
R1
5.1kΩ
1206
LIZ
CR06T05NJ5K1
1
R2
R3,
R17
300kΩ
DIP
Any
Any
1206
Yageo
RC1206FR-07499KL
1
R4
8.2kΩ
0603
Yageo
RC0603FR-078K2L
1
R5
20Ω
1206
Yageo
RC1206JR-0720RL
1
R6
845kΩ
0603
Yageo
RC0603FR-07845KL
1
R7
4.87kΩ
0603
Yageo
RC0603FR-074K87L
1
R8
20Ω
0805
Yageo
RC0805JR-0720RL
2
2
330μF/50V
499kΩ
CBB, 450V
Ceramic Cap, 50V,
X7R
Ceramic Cap, 50V,
X7R
Ceramic Cap, 10V,
X7R
Ceramic Cap, 50V,
COG
Ceramic Cap, 630V,
X7R
N-MOS, 8A, 700V
Thick Film Chip RES,
5%
Metal Film RES, 1W
Thick Film Chip RES,
1%
Thick Film Chip RES,
1%
Thick Film Chip RES,
5%
Thick Film Chip RES,
1%
Thick Film Chip RES,
1%
Thick Film Chip RES,
5%
SS-5-2A
TP4M1.2-02
TP4U300-00
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
5
EV4026-J-00C– EVB DESCRIPTION
EV4026-J-00C BILL OF MATERIALS (continued)
Qty
Ref
Value
1
R9
1kΩ
1
R10
500mΩ
1
R11,
R12
R13
NS
1
R14
30kΩ
2
1.1Ω
1
R15,
R16
RV1
430V/2500A
1
T1
FX0327
1
U1
MP4026
2
680kΩ
Description
Thick Film Chip RES,
1%
Thick Film Chip RES,
1%
Thick Film Chip RES,
1%
Thick Film Chip RES,
1%
Thick Film Chip RES,
1%
Zinc Oxide Varistor
EDR2609,
Lp=740μH,
Np:Ns:Naux=40:10:7
LED Lighting
Controller
Package
Manufacturer
Manufacturer_P/N
0603
Yageo
RC0603FR-071KL
1206
Yageo
RC1206FR-070R5L
1206
Yageo
RC1206FR-071R1L
1206
Yageo
RC1206FR-0730KL
1206
Yageo
RC1206FR-07680KL
DIP
TKS
TVR10431KSY
EDR2609
Emei
EDR26P8U740-00
FCTSOT-6
MPS
MP4026GJ-Z R0
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
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© 2013 MPS. All Rights Reserved.
6
EV4026-J-00C– EVB DESCRIPTION
TRANSFORMER SPECIFICATION
Electrical Diagram
1
6
N1
N3
8
3
4
Sec. Side
N2
5
4
Copper foil
WINDING START
TFL TUBE
Pri. Side
Figure 4 – Transformer Electrical Diagram
Notes: Wind copper foil (3.0mm x 0.025mm) to circle the side of transformer and connect to PIN4
Winding Diagram
1T
N3
1T
N2
1T
N1
Figure 5 – Winding Diagram
Winding Order
Winding No.
N1
N2
N3
Tape Layer Number
1
1
1
Start & End
3→1
5→4
6→8
Magnet WireΦ(mm)
0.3*1
0.18*1
0.4*1 (T.I.W)
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
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© 2013 MPS. All Rights Reserved.
Turns
40
7
10
7
EV4026-J-00C– EVB DESCRIPTION
Electrical Specifications
Electrical Strength
1 second, 50Hz, from Pins 1, 3, 4, 5 to 6, 8
Primary Inductance
Pins 1-3, all other windings open, measured at 10kHz, 0.1
VRMS
3500VAC
740μH±10%
Materials
Item
1
2
3
4
5
6
7
8
9
10
Description
2
Core: EDR2609, UI=2300±25%, AL=462.5nH/N ±3% GAPPED, PC4
Bobbin: EDR26 T-H, 8PINS, 1SEC, T375J, PINL=4.0±0.2mm
Wire: Φ0.18mm, Φ0.20mm, Φ0.30mm, 2UEW, CLASS F
Triple Insulation Wire: Φ0.40mm,TRW(B)
Tape: 4.0mm(W)×0.06mm(TH), Yellow; 5.0mm(W)×0.06mm(TH), Yellow
Copper foil: 3.0mm(W)×0.025mm(TH)
Tube:AWG#23 CLEAR; AWG#30 CLEAR
Varnish: BC-346A
Epoxy: E-500
Solder Bar: SN99.5/Cu0.5
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
8
EV4026-J-00C– EVB DESCRIPTION
EVB TEST RESULTS
Performance Data
f
(Hz)
60
50
VIN
(VAC)
PIN
(W)
VOUT
(V)
I12LEDs
(mA)
POUT
(W)
η
(%)
PF
I11LEDs
(mA)
I10LEDs
(mA)
I9LEDs
(mA)
I8LEDs
(mA)
I7LEDs
(mA)
I6LEDs
(mA)
90
100
110
120
135
150
170
185
200
220
230
240
250
264
21.64
21.49
21.37
21.28
21.21
21.16
21.13
21.17
21.25
21.29
21.34
21.39
21.45
21.54
36.36
36.35
36.35
36.34
36.34
36.33
36.32
36.31
36.3
36.29
36.29
36.28
36.28
36.27
500
501
502
502
502
502
503
503
503
504
504
505
505
506
18.18
18.21
18.25
18.24
18.24
18.24
18.27
18.26
18.26
18.29
18.29
18.32
18.32
18.35
84.01
84.74
85.39
85.73
86.01
86.19
86.46
86.27
85.92
85.91
85.71
85.65
85.41
85.20
0.994
0.993
0.992
0.99
0.987
0.983
0.975
0.969
0.961
0.947
0.94
0.932
0.923
0.91
505
506
506
507
507
507
507
508
508
509
509
510
510
511
511
511
512
512
512
512
512
513
514
514
515
516
516
517
514
514
514
514
514
514
515
515
516
517
517
518
519
519
519
519
519
519
519
519
520
521
522
523
524
524
525
526
525
525
525
525
525
525
526
527
527
529
529
530
531
532
528
528
529
529
529
529
530
531
532
534
535
535
536
537
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
21.51
188.2
230/50
21.32
98.35
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
140.90
78.74
41.44
20.72
14.50
12.27
10.64
9.38
8.40
7.60
6.94
6.38
5.91
5.50
5.15
4.83
4.56
4.31
4.09
16.9
3.12
0.67
0.55
0.65
0.76
0.85
0.87
0.78
0.88
0.85
0.73
0.72
0.77
0.65
0.66
0.61
0.54
0.59
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
71.16
39.77
20.93
10.46
7.33
6.19
5.37
4.74
4.24
3.83
3.50
3.22
2.98
2.77
2.59
2.44
2.30
2.17
2.06
12.52
3.92
3.16
1.8
0.58
0.38
0.45
1.21
1.47
1.02
0.47
0.46
0.44
0.38
0.52
0.63
0.47
0.44
0.6
14.28
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-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
9
EV4026-J-00C– 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-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
10
EV4026-J-00C– EVB DESCRIPTION
EVB TEST RESULTS
Performance waveforms are tested on the evaluation board.
12 LEDs in series, ILED=500mA, VOUT=36V.
5%
100
1.00
4%
95
0.95
90
0.90
1%
0
85
0.85
80
0.80
-1%
75
0.75
70
0.70
-4%
65
0.65
-5%
90 110 130 150 170 190 210 230 250 270
60
90 110 130 150 170 190 210 230 250 270
0.60
90 110 130 150 170 190 210 230 250 270
3%
2%
-2%
-3%
120
110
EN55015O
100kHz
1 MHz
10 MHz
120
110
EN55015O
100kHz
1 MHz
10 MHz
120
110
100
100
100
90
90
90
80
80
80
70
70
70
60
60
50
50
EN55015A
60
40
40
30
30
30
20
20
20
10
10
10
0
0
120
110
30MHz
9kHz
CDN_QP
50
EN55015A
40
9kHz
100 MHz
30MHz
0
30MHz
300MHz
100 MHz
100
90
80
70
60
CDN_QP
50
40
30
20
10
0
30MHz
300MHz
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
11
EV4026-J-00C– EVB DESCRIPTION
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
12 LEDs in series, VIN=120VAC/60Hz, ILED=500mA, VOUT=36V.
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
12
EV4026-J-00C– EVB DESCRIPTION
EVB TEST RESULTS (continued)
Performance waveforms are tested on the evaluation board.
12 LEDs in series, VIN=230VAC/50Hz, ILED=500mA, VOUT=36V.
EV4026-J-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
13
EV4026-J-00C– 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-00C Rev.1.1
www.MonolithicPower.com
12/30/2013
MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited.
© 2013 MPS. All Rights Reserved.
14
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