EV4068-S-00A 108VAC~132VAC/60Hz, 50V/140mA Low Cost, Small Form Factor High PFC Off-line Dimmable LED Driver Evaluation Board DESCRIPTION FEATURES The EV4068-S-00A Evaluation Board is designed to demonstrate the capabilities of MP4068. The MP4068 is a highly integrated TRIAC dimmable LED driver with high power factor. It is specifically designed for low-line input (120VAC), no-isolated, TRIAC-dimmable LED lighting applications, especially for the low cost and small form factor applications. The integrated 500V MOSFET ensures the system to withstand 500V surge test without MOV or TVS. Only a single winding inductor is required to realize the solution. It features MPS’s proprietary hybrid operation mode which is designed to achieve good dimming performance. The EV4068-S-00A is typically designed for driving an 7W Triac dimmable LED bulb with 50VTYP, 140mA LED load from 108VAC to 132VAC, 60Hz. The EV4068-S-00A has an excellent efficiency and meets IEC61547 surge immunity, IEC61000-3-2 Class C harmonics and EN55015 conducted EMI requirements. It has multi-protection function as over-voltage protection; output short-circuit protection, thermal shut down, etc. ELECTRICAL SPECIFICATION Parameter Symbol Value Units Input Voltage Output Voltage LED Current Output Power Efficiency (full load) VIN VOUT ILED POUT η 108 to 132 50 140 7 >84 VAC V mA W % Power Factor THD PF THD >0.9 <41 % Excellent TRIAC Dimming Performance Lowest Cost BOM Constant Current LED Driver Good LED Current Accuracy 500V MOSFET Integrated Internal HV Fast Start-Up Single Winding Inductor High Power Factor(>0.9) High Efficiency (>84%) LED Current Foldback at High Temperature Thermal Shutdown (Auto Restart with Hysteresis) VCC Under Voltage Lockout with Hysteresis (UVLO) Programmable Over Voltage Protection Output Short Circuit Protection Fit inside GU10 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. EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 1 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER EV4068-S-00A EVALUATION BOARD (L x W x H) 35mm x 23mm x 15mm Board Number MPS IC Number EV4068-S-00A MP4068GS 2 4 600V/1A DSF1J 3.3uF/100V/1206 1 D 2 R 1 1 K 9 9 4 K 8 2 3 LED+ 2 50V/140mA 5 4 6 8 R 9 51K/0805 1 200/1W 5 R LED- SSN1N45BTA 450V/0.5A Q K 0 3 K 1 5 330uF/63V 250V/1A R ES1J/600V/1A R N C 1 D 20/0805/1% 1 F R11 330nF/10V TVR07241 C 108VAC-132VAC 600V/1A EE10/1mH 1.1/0805/1% 1 V R MP4068GS DSF1J 3 R L 220nF/450V 1M/0.25W 68pF/630V/1206 R10 D 3 C 10K/0805 C 1 7 R 2.2uF/10V 600V/0.5A C MB6S R 10mH/15 B L 100K/0805 1 U 1 L R D 6 C EVALUATION BOARD SCHEMATIC Figure 1—Schematic EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 2 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER PCB LAYOUT (SINGLE-SIDED) Figure 2—Top Layer Figure 3—Bottom Layer EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 3 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER CIRCUIT DESCRIPTION The EV4068-S-00A is configured in a singlestage Buck topology and gets a cost effective BOM. It also achieves high power factor and excellent TRIAC dimming performance. F1, RV1, L1, R7, 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 for surge test. L1, R7 and C2 form an EMI filter. The diode rectifier BD1 rectifies the input line voltage. C7, L3 and C3 form a π structure EMI. R12, C8 are used as a bleeder circuit which keeping the TRIAC current above the minimum holding current after TRIAC turns on. R8, R9, R10, R5, Q1 with C5 compose the active damping circuit. It helps to reduce the inrush current through dimmer at the moment dimmer turning on. The circuit let the inrush current flow through R5 at the moment TRIAC dimmer turning on. Then Q1 turns on and shorts R5, this saves power loss from R5. The R10 connected from bus provides a bias voltage for the gate driver of Q1, which also save power loss of Q1. R4, D2, C1 and C6 are used to supply the power for MP4068. At normal work, the power is charged by the internal high voltage regulator from HV pin. But in deep dimming condition, the power may not be enough supplied only by the high voltage regulator, the diode D2 connected to output will help maintain the power supply voltage. R1 and R2 are used to monitor the output OVP condition. The OVP voltage is set by the divider ratio of R1 and R2. R3, R11 are sensing resistors for LED current control. The value of R3 and R11 set the output LED current. Diode D1 is the Buck fly-wheel diode, the inductor L2 and the capacitor C4 are the output filter. The resistor R6 is placed as a dummy load to consume the output power in open load condition. The diode D3 is used to prevent the output current flowing back to IC when input Sine voltage drops lower than output voltage. EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 4 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER EV4068-S-00A BILL OF MATERIALS Qty Ref Value 1 C1 2.2µF/10V 1 C2 68pF/630V 1 C3 220nF/450V 1 C4 330µF/63V 1 C5 330nF/10V 1 C6 3.3µF/100V 1 BD1 MB6S 1 D1 ES1J Diode, 1A, 600V DSF1J Diode, 1A, 600V 1 1 D2, D3 F1 L1 250V/1A 10mH 1 L2 1mH 1 Q1 SSN1N45B TA 1 R1 18kΩ 1 R2 499kΩ 1 R3 1.1Ω 1 R11 20Ω 1 R4 100kΩ 1 R5 200Ω/1W 1 R6 51kΩ 1 R7 10kΩ 1 R8 30kΩ 1 R9 51kΩ 1 R10 1MΩ/0.25W 1 RV1 TVR07241 2 Description Ceramic Cap, 10V, X7R Ceramic Cap, 630V, C0G CBB, 450V Electrolytic Capacitor, 63V Ceramic Cap, 10V, X7R Ceramic Cap, 100V, X7S Rectifier Bridge, 600V, 0.5A Fuse Inductor Inductor, Φ0.23mm, 180 turns N-Channel MOSFET Thick Film Chip Res, 1% Thick Film Chip Res, 1% Thick Film Chip Res, 1% Thick Film Chip Res, 1% Thick Film Chip Res, 5% Metal Film Res, 1W, 5% Thick Film Chip Res, 5% Thick Film Chip Res, 5% Thick Film Chip Res, 1% Thick Film Chip Res, 1% Metal Film Res, 1W, 5% MOV Package Manufacturer 0603 muRata GRM188R71A225KE15D 1206 muRata GRM31A7U2J680JW31D DIP Fara DIP Jianghai 0603 HHEC C0603X334K010T 1206 TDK C3216X7S2A335K SOIC-4 SMA Taiwan Semiconductor Taiwan Semiconductor Manufacture_P/N C222S224K31C000 CD263-63V330 MB6S ES1J SOD123FL DIP DIP Little fuse Hulsin EE10 Emei TO-92 Fairchild 0603 Yageo RC0603FR-0718KL 0603 Yageo RC0603FR-07499KL 0805 Yageo RC0805FR-071R1L 0805 Yageo RC0805FR-0720RL 0805 Yageo RC0805JR-07100KL DIP Any 0805 Yageo RC0805JR-0751KL 0805 Yageo RC0805JR-0710KL 0603 Yageo RC0603FR-0730KL 0603 Yageo RC0603FR-0751KL DIP Any 1MΩ/0.25W DIP TKS TVR07241 SXY DSF1J 39211000000 HDR0810-103K-N5 SSN1N45BTA 200Ω/1W EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 5 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER EV4068-S-00A BILL OF MATERIALS (continued) Qty Ref Value 1 JR1 0Ω 1 U1 MP4068GS 4 L,N, LED +,LE D_ 1.0 公针 Description Thick Film Chip Res, 5% Triac-dimmable LED Lighting Controller Package Manufacturer Manufacture_P/N 0805 Yageo RC0805JR-070RL SOIC8-7 MPS MP4068S-CU10 R4 1.0 公针 EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 6 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER TRANSFORMER SPECIFICATION Electrical Diagram Figure 4—Transformer Electrical Diagram Winding Diagram Pin Side Pin Side 3Ts N1 1T Figure 5—Winding Diagram EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 7 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER Winding Order Winding No. N1 Tape Layer Number 1 3 Start & End Magnet Wire Φ(mm) Turns 8→1 0.23mm * 1 180 Electrical Specifications Electrical Strength 60 second, 60Hz, from Winding to CORE. 1000VAC Primary Inductance Pins 1 - 8, all other windings open, measured at 100kHz, 0.1 VRMS 1mH±8% Materials Item 1 2 3 4 5 6 Description Core: EE10, UI=2500±25%, AL=221.5H/N2±2% GAP, ACME P4 or equivalent Bobbin: EE10, 4+4PIN RMMOVE PIN2,3,4,6,7 Wire: Φ0.23mm, 2UEW, CLASS F or equivalent Tape: 6.5mm(W)×0.06mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 8 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER EVB TEST RESULTS Performance Data Efficiency, PF and THD f (Hz) 60 Vin(V) Pin(W) Vo(V) Io(mA) Po(W) Efficiency (%) PF THD (%) 108 7.64 48.4 133 6.44 84.3 0.954 30.9 120 8.08 48.8 141 6.88 85.2 0.94 35.6 132 8.44 49 147 7.20 85.3 0.923 40.5 Dimming Compatibility (No Flicker with these 31 different Dimmers) Dimmer No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Manufacturer Part No. LUTRON LUTRON LUTRON LUTRON LUTRON LUTRON LUTRON LEVITON LEVITON LEVITON LUTRON LUTRON LUTRON LUTRON LUTRON LUTRON LEVITON LUTRON LUTRON Q-600P-IV CN-600P AY-600P SLV-600P LG-600P 6B38-Q-600P GL-600H-DK 1G40O5 1I20O5 6633-P 6B38-S-600P CT-600P 6B38-S-603PG 6B38-DV-600P DVCL-153P 6B38-DVLV-600P 1L10O5 GLS01-C06570 DV-600P-BR 20 LEVITON 6613-PL 21 22 23 24 25 LEVITON LUTRON LUTRON LUTRON LUTRON C20-6684-IW AY-600P-LA TG-600PH-WH TG-603GH-WH S-600 26 LUTRON DVPDC-203P-WH 27 28 29 30 31 LUTRON LUTRON LUTRON COOPER LEVITON S-600P 6B38-DV-603PG DNG-603PH-WH 6B28 6633-P-1G10O5 Power Stage 600W Incandescent 600W 600W 600W 600W 600W 600W Incandescent 600W 600W 600W 600W 600W 600W 600W 600W 600W 600W 600W 600W Incandescent 600W Magnetic low voltage 600W Incandescent 600W Incandescent 600W 600W 600W 200W for Philips dimmable CFL 600W 600W 400W 600W 600W Imax (mA) 126 109 109 110 110 111 119 111 127 126 108 105 84 105 100 107 109 82 106 Imin (mA) 7 2 2 2 2 2 1 0 0 0 2 4 1 4 31 5 2 0 3 125 1 131 111 108 79 117 1 3 4 4 2 115 45 105 83 100 113 125 2 3 0 1 2 EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 9 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER Electric Strength Test 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 surge testing was completed according to IEC61547. Input voltage was set at 120VAC/60Hz. 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 -500 120 120 L to N L to N 90 270 Pass Pass Thermal Test Test without dimmer and with dimmer at 50% dimming on phase. Chip: 67.5℃ Without dimmer Chip: 54.2℃ With dimmer at 50% dimming on phase Transformer: 57.4℃ Without dimmer Damping MOS: 66.6℃ With dimmer at 50% dimming on phase EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 10 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VIN=120VAC/60Hz, 16 LEDs in series, ILED=140mA, VOUT=50V, L=1mH. EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 11 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN=120VAC/60Hz, 16 LEDs in series, ILED=140mA, VOUT=50V, L=1mH. EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 12 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VIN=120VAC/60Hz, 16 LEDs in series, ILED=140mA, VOUT=50V, L=1mH. EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 13 EV4068-S-00A – LOW LINE VOLTAGE, 7W LOW COST DIMMABLE LED DRIVER QUICK START GUIDE 1. Preset AC Power Supply to 108VAC VIN 132VAC. 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 (“L” and “N”) 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. 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. EV4068-S-00A Rev.1.0 www.MonolithicPower.com 10/28/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 14