LV5011MD-GU10-120VEVM02 [ For GU10 Application ] The Buck-Boost Converter for phase cut dimming with High Power Factor Application Note Ver1.02 LV5011MD-GU10-120VEVM02 Application Note 1. Introduction 2. Features 3. Performance Specifications 3.1. Application constitution 3.2. Electrical characteristics 4. Schematic 5. Evaluation Board 6. Test Setup 7. Test Procedure 7.1 Line/Load Regulation and Efficiency Measurement Procedure 7.2 Equipment Shutdown 7.3 Phase Angle Decode vs LED Current (at dimming) 8. Performance Data 8.1 Efficiency 8.2 Power factor 8.3 Line regulation 8.4 Output voltage/current operation waveform (No dimming) 8.5 Input voltage/current operation waveform (No dimming) 8.6 LED current vs Phase angle 8.7 Dimming operation waveform 8.8 EMI data 9. Board Layout 10. Bill of materials 11. Transformer specification 12. Detailed Descriptions for Application Circuit Setting 12.1 REF_IN pin setting 12.2 Transformer design 12.3 CS pin setting 12.4 Startup resistor setting 12.5 Protection function 1. Introduction The LV5011MD-GU10-120VEVM02 is a 6W, 120VAC non-isolated dimmable LED driver for GU10 application. The LV5011MD-GU10-120VEVM02 is a Buck-Boost Converter used for commercial and residential phase-cut dimmer compatible LED lamp drivers. 2. Features ・Non-isolated Buck-Boost converter ・Small size application ・Compatible With Leading and Trailing Edge Dimmer ・High Power Factor & Improved THD ・Short Protection - [latch off] ・Over Voltage Protection - [auto recovery] ・Thermal Protection - [auto recovery] 3. Performance Specifications 3.1. Application constitution Non-isolation Buck-Boost with Phase Cut Dimming 3.2. Electrical characteristics (Operating Temperature = 25C) Table1. LV5011MD-GU10-120VEVM02 Electrical Performance Specifications Description Min Typ Max Units Input AC voltage 108 120 132 VAC Output voltage 40 V Output current 120 mA Efficiency 81 % Power Factor 0.78 Comment VAC=120V, 60Hz VAC=120V, 60Hz 4. Schematic LED+ R10 22k AC F1(Fuse) R2 1k/1W 33/1W VR1 271 AC INPUT AC C1 0.022uF /275VAC R1 D1 R11 10k L1 1.5mH C3 0.047uF /630V C2 0.1uF /630V C6 100uF/50V LED- C4 0.22uF /630V R6 330k 33/1W 4 LEDs in series [LED: OSW4Z3E1C1E] D3 MBRS3200 5 1 3 R9 D2 MMSD103 C5 4.7uF/50V 7 100 6 T1 Core: EE13 (WE part No,750341938) R3 1.2M Transformer T1 specifications Inductance value 5-3 inductance L1 = 1.3mH 5-1 inductance L2 = 110uH Turns ratio (5-1) : (6-7) = 2.2 : 1 1 2 3 4 5 R4 10k R5 0 LED Source Drain NC NC VIN LV5011 GND U1 9 8 CS 7 REF_IN 6 ACS OUT2 10 LV5011MD Figure1. LV5011MD-GU10-120VEVM02 Schematic R7 Open R8 1.8 5. Evaluation Board AC INPUT LED+ Figure2. LV5011MD-GU10-120VEVM02 Transformer Side LED- 35mm 16.5mm Figure3. LV5011MD-GU10-120VEVM02 IC Side 6. Test Setup 6.1 Test Equipment Voltage Source: 120VAC AC source, NF EPO2000S Power Meter: HIOKI 3332 Volt Meter: ADVANTEST R6441D DIGITAL MULTIMETER AMP Meter: Agilent DIGITAL MULTIMETER 34401A Output Load: 4 LEDs series (LED: OSW4Z3E1C1E) Oscilloscope: LeCroy WaveRunner 6050A Operating Temperature: 25℃ 6.2 Recommended Test Setup Volt Meter + Power Meter AMP Meter Neutral AC Source AC INPUT LED + LV5011MD-GU10-120VEVM02 Line Dimmer Min At No Dimming, Connect this line LED- Max LED Figure4. LV5011MD-GU10-120VEVM02 Recommended Test Set Up 6.3 List of Test Points Table2. Test Points Functions TEST POINTS NAME DESCRIPTION Neutral 120VAC neutral connection Line 120VAC line voltage LED+ LED anode connection LED- LED cathode connection 7. Test Procedure 7.1 Line/Load Regulation and Efficiency Measurement Procedure 1. Connect LV5011MD-GU10-120VEVM like upper Figure4. An external LED load must be used to start up the EVM. 2. Prior to turning on the AC source, set the voltage to 120VAC. 3. Turn on the AC Source. 4. Record the output voltage readings from Volt Meter and the output current reading from AMP Meter. And Record the input power reading from Power Meter. 5. Change VAC from 108VAC to 132VAC and perform “4”. 6. Refer to Section 7.2 for shutdown procedure. 7.2 Equipment Shutdown 1. Turn off equipment. 2. Make sure capacitors are discharged. 7.3 Phase Angle Decode vs LED Current (at dimming) 1. Connect LV5011MD-GU10-120VEVM like upper Figure4. An external LED load must be used to start up the EVM. 2. Prior to turning on the AC source, set the voltage to 120VAC. 3. Monitor the Dimmer output AC voltage between the neutral and the line by using the oscilloscope differential probe. 4. Turn on the AC Source. 5. Maximize the dimmer ratio. 6. Record the output voltage readings from Volt Meter and the output current reading from AMP Meter. And Record the input power reading from Power Meter. And Record the phase angle of Dimmer output reading from the oscilloscope differential probe. 7. Gradually lower the Dimming ratio and perform "6". Repeat it until the Dimming ratio is minimized. 8. Refer to Section 7.2 for shutdown procedure. 8. Performance Data 8.1 Efficiency Efficiency vs Input Voltage 84 50Hz 60Hz Efficiency [ % ] 82 80 78 76 74 100 110 120 130 140 Input Voltage [ VAC ] Figure5. Efficiency vs Input voltage 8.2 Power factor Power Factor vs Input Voltage 0.85 50Hz 60Hz Power Factor 0.80 0.75 0.70 0.65 100 110 120 130 Input Voltage [ VAC ] Figure6. Power factor vs Input voltage 140 8.3 Line regulation LED Current (Output current) LED Current vs Input Voltage 150 50Hz 145 60Hz 140 LED Current [ mA ] 135 130 125 120 115 110 105 100 100 110 120 130 140 Input Voltage [ VAC ] Figure7. LED current vs Input voltage Output Voltage Output Voltage vs InputVoltage 40.6 40.4 50Hz 40.2 60Hz Output Voltage [ V ] 40.0 39.8 39.6 39.4 39.2 39.0 38.8 38.6 100 110 120 130 140 Input Voltage [ VAC ] Figure8. Output voltage vs Input voltage 8.4 Input voltage/current operation waveform (No dimming) CH1 Input voltage (VAC) [200V/div] CH4 Input current [200mA/div] 5msec/div Figure9. Input waveform 8.5 Output voltage/current operation waveform (No dimming) CH1 Output voltage [10V/div] CH4 Output current (LED current) [100mA/div] 5msec/div Figure10. Output waveform 8.6 LED Current vs Phase angle [ Measurement condition: V AC=120V, 60Hz, Dimmer=LEVITON IPI06 ] LED Current vs Phase angle 140 LED Current [mA] 120 100 80 60 40 20 0 0 20 40 60 80 100 120 140 160 180 phase angle [ deg ] Figure11. LED current vs Phase angle 8.7 Dimming operation waveform [ Measurement condition: V AC=120V, 50Hz, Dimmer=LEVITON IPI06 ] Phase angle = 120 degree CH1 Input voltage =Dimmer output [100V/div] CH4 Input current [200mA/div] 5msec/div Figure12. Dimming operation waveform at phase angle=120degree Phase angle = 60 degree CH1 Input voltage =Dimmer output [100V/div] CH4 Input current [200mA/div] 5msec/div Figure13. Dimming operation waveform at phase angle=60degree 8.8 EMI data Conducted Emission QP Measurement [ Measurement condition: V AC=120V, 60Hz ] Phase1 Phase2 Figure14. Conducted Emission, QP Measurement 9. Board Layout Figure15. Transformer Side Layout Figure16. IC Side Layout Figure17. Board Size 10. Bill of materials No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Designator Description Value Footprint Manufacturer Model Number C1 C2 C3 C4 C5 C6 D1 D2 D3 L1 F1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 T1 U1 VR1 0.022uF/AC275V 0.1uF/630V 0.047uF/630V 0.22uF/630V 4.7uF/50V 100uF/50V 600V/0.8A 250V/0.2A 200V/3A 1.5mH 33, 1W 33, 1W 1kΩ, 1W 1.2Meg 10k 0 330k 1.8 100 22k 10k Radial Radial Radial Radial 1206 8*11.5 1Z(SMD) SOD-123 SMB 5*6.5 Axial Axial Axial 0805 0603 0603 1206 0805 0603 0603 0603 EE13 SOIC10 Radial Okaya Murata Murata Murata Murata Rubycon Shindengen Onsemi Onsemi sumida Panasonic Panasonic Panasonic ROHM KOA KOA ROHM ROHM KOA KOA KOA WE Midcom Onsemi Nippon Chemicon LE223 RDER72J104K8K1C11B RDER72J473K3K1C11B RDER72J224K5B1C13B GRM31CR71H475KA 50ZLH100M S1ZB60 MMSD103T1G MBRS3200T3G RCH4764NP-152K ERQ1ABJ330 ERG1SJ330 ERG1SJ102 KTR10PZPZF1204 RK73H1JTTDF103 RK73Z1JTTD000 ESR18PZPZJ334 MCR10PZHZFL1R80 RK73K1JTDJ101 RK73H1JTTDF223 RK73H1JTTDF103 750341938 Rev.01 LV5011MD TND05V-271KB Metallized Polyester Film Capacitor Ceramic Capacitor, X7R Ceramic Capacitor, X7R Ceramic Capacitor, X7R Ceramic Capacitor, X7R Aluminum Electrolytic Capacitor Bridge Diode Diode Schottky Rectifiers Inductor Metal Film Fuse Resistor Metal Film Resistor Metal Film Resistor Chip Resistor Chip Resistor Chip Resistor Chip Resistor Open Chip Resistor Chip Resistor Chip Resistor Chip Resistor Transformer LED Driver Varistor AC175V 11.Transformer specification 12.Detailed Descriptions for Application Circuit Setting The LV5011MD-GU10-120VEVM02 is the non-isolated buck-boost converter with phase cut dimming. The explanation of each parts of the application circuit is described in figure18. How to set this application circuit is described below. Capacitor for smoothing output voltage LED+ R10 22k AC F1(Fuse) 33/1W VR1 271 AC INPUT AC R1 C1 0.022uF /275VAC D1 R2 1k/2W R11 10k L1 C2 0.1uF /630V 1.5mH C3 0.047uF /630V 33/1W C4 0.22uF /630V D3 MBRS3200 R6 330k (LED 4 series) (LED: OSW4Z3E1C1E) 5 Start up resistor for HV regulator Snubber circuit for TRIAC dimming Transformer T1 specifications Inductance value 5-3 inductance L1 = 1.3mH 5-1 inductance L2 = 110uH Turns ratio (5-1) : (6-7) = 2.2 : 1 3 Capacitor for VIN supply Transformer 7 6 100 D2 MMSD103 R3 1.2M [OUTPUT=40V/120mA] 1 R9 C5 4.7uF/50V T1 Core: EE13 (WE part No,750341938) Auxiliary winding for VIN supply U1 LV5011MD 1 2 Resistors for REF_IN setting 3 4 5 R4 10k R5 0 Connect ACS pin to GND Drain Source NC NC VIN GND ACS OUT2 CS LED LED- Rectifier diode Filter for EMI and TRIAC dimming Filter for EMI and TRIAC dimming C6 100uF/50V 10 9 8 7 Current sense resistor 6 REF_IN R7 Open Figure18. The description of each parts of LV5011MD-GU10-120VEVM02 R8 1.8 12.1 REF_IN pin setting R3, R4, R10, R11 setting R3, R4, R10 and R11 is connected as shown in Figure19. Please set R3, R4, R10 and R11 so that the peak voltage of the REF_IN pin is between 1.3V and 1.7V, in addition the minimum voltage of the REF_IN pin is between 0.1V and 0.2V. The peak voltage and the minimum voltage of the REF_IN pin are shown in the following expressions. Please set R3, R4, R10 and R11 to satisfy these expressions. LED+ R10 AC INPUT C6 VOUT D1 R11 LEDR3 REF_IN R4 Figure19. REF_IN pin setting R4 R11 REF_IN peak = R3+R4 × VAC peak + R10+R11 × VOUT = 1.3 ~ 1.7 [V] R4 R11 REF_IN min = R3+R4 × R10+R11 × VOUT = 0.10 ~ 0.15 [V] however, R3+R4 R10+R11 > 30 Where VAC peak : Input peak voltage VOUT : Output voltage (LED voltage) e.g. VAC(RMS)=120V, VOUT =40V R3=1200kΩ, R4=10kΩ, R10=22kΩ, R11=10kΩ 10 10 REF_IN peak = 1200+10 × 120× 2 + 22+10 × 40 = 1.51 [V] 10 10 REF_IN min = 1200+10 × 22+10 × 40 = 0.10 [V] 12.2 Transformer design At first calculate the inductance “L1” which is used at Internal MOSFET “ON”. The inductance “L1” is calculated (VAC peak) 2 × D1 2 × 0.0813 L1 = POUT × f LED+ where, L1 : Inductance which is used at internal MOSFET “ON” VAC peak : Input peak voltage f : Switching frequency = 70k [Hz] POUT : Output power POUT = VOUT × IOUT VOUT : Output voltage (LED voltage) IOUT : Output current (LED current) D1 : Duty of Internal MOSFET “ON” Vf LED- Rectified AC voltage Drain pin L2 [Turns: N2] L1 [Turns: N1] VIN pin [Turns: Nd] T1 D1 = T Transformer T1 : Time of internal MOSFET “ON” T : Switching period = 1/70k [sec] Figure20. Transformer Inductance and Turns At second calculate the inductance “L2” which is used at the rectifier diode “ON”. (VOUT + Vf ) 2 × D2 2 L2 = L × (I peak) 2 × f 2 1 1 Transformer current I2 peak Internal MOSFET current where, L2 : Inductance which is used at the rectifier diode “ON” Vf : Forward voltage of the rectifier diode I1 peak Rectifier diode current I1 peak : Peak current of L1 (*Refer to section “12.3”) D2 : Duty of the rectifier diode “ON” T2 D2 = T T1 T2 T2 : Time of the rectifier diode “ON” Confirm the peak current of L2 “I2 peak”. “I2 peak” is determined below. I2 peak = Time L1 L2 × I1 peak Choose a rectifier diode permitting “I2 peak”. T Figure21. Transformer current Next calculate about Turns Raito of “L1” and “L2”. N1 N2 = L1 L2 where, N1 : Turns of “L1” N2 : Turns of “L2” Design the most suitable transformer with the winding turns ratio and the inductance value. Confirm that the operation with the designed transformer is a current discontinuous mode. The auxiliary winding turns “Nd ” is calculated Nd VIN = N2 VOUT where, Nd : Turns of auxiliary winding VIN : VIN pin voltage 12.3 CS pin setting R7, R8 setting The output power is set by the current sense resistor (R7, R8) connected to CS pin. The current sense resistor is calculated, L1 × f × 0.183 POUT R7 × R8 R7 + R8 = Figure18 is the operation outline diagram. Internal MOSFET current (= L1 current) CLK - VREF L1 REF_IN 1.3V~1.7V LV5011MD inside REF_IN Rectified AC voltage Q RESET Internal MOSFET current (= L1 current) Reference VREF (0.605Vtyp) Internal MOSFET + (0.605Vtyp) T ON Internal MOSFET Gate CS R7 OFF Ton R8 Reference =REF_IN Toff Reference =0.605V Figure22. Operation outline diagram (No dimming) Reference =REF_IN The peak current of L1 “I1 peak” is the following expression. R7 + R8 I1 peak = R7 × R8 × 0.605 ( In the case of REF_IN > VREF(0.605V) ) Please design the transformer and set the current sense resistor (R7, R8) so that “I1 peak” does not exceed 0.5A. 12.4 Startup resistor setting R6 setting Startup resistor “R6” provides electric power from the rectified AC voltage to VIN pin. When the voltage of VIN pin reaches 9Vtyp, LV5011MD starts switching operation. After operation start, power consumption from the rectified AC voltage by R6 is reduced by the auxiliary winding of transformer. When the input is 120VAC, the recommended value of R6 is 330kΩ. D1 T1 R6 LV5011MD VIN D2 C5 Figure23. Startup resistor “R6” setting 12.5 Protection function 1 2 3 4 tilte UVLO OCP OVP OTP outline Under Voltage Lock Out Over Current Protection Over Voltage Protection Over Temperature Protection monitor point VIN voltage CS voltage VIN voltage PN Junction temperature 1. UVLO(Under Voltage Lock Out) If VIN voltage is 7.3V or lower, then UVLO operates and the IC stops. When UVLO operates, the power supply current of the IC is about 120uA or lower. If VIN voltage is 9V or higher, then the IC starts switching operation. VIN voltage VIN voltage UVLOON (9Vtyp) UVLOOFF (7.3Vtyp) time Output stage on off on 2. OCP(Over Current Protection) CS pin is used to sense current in primary winding of transformer via internal HV MOSFET. This provides an additional level of protection in the event of a fault. If the voltage of the CS pin exceeds VCSOCP(1.9Vtyp.)(A), the internal comparator will detect the event and turn off the MOSFET. The peak switch current is calculated Iocp(peak)[A] = VCSOCP[V] / Rcs[Ω] The VIN pin is pulled down to fixed level, keeping the controller latched off. The latch reset occurs when the user disconnects LED from VAC and lets the VIN falls below the VIN reset voltage,UVLOOFF(7.3Vtyp.)(B). Switching restarts when VIN rises to UVLOON(9Vtyp.)(C). CS voltage A C VCSOCP(1.9Vtyp) time VIN voltage B UVLOON(9Vtyp) UVLOFF(7.3Vtyp) time Output stage on off on 3. OVP(Over Voltage Protection) If the voltage of VIN pin is higher than the internal reference voltage VINOVP(27Vtyp), switching operation is stopped. The IC(device) will not restart till reset voltage <7.3V and then rise to 9V. Please see OVP waveform chart. OVP reset OVP VIN voltage Operation start 27Vtyp 9Vtyp 7.3Vtyp time Output stage on off on 4. OTP(Over Thermal Protection) The over temperature protection stops the switching operation of the IC in case the junction temperature reaches 165°C(typ.)(A). The IC starts switching operation again when the junction temperature is 135°C(typ.)(B) or lower. Please see OTP waveform chart. Tj (Junction Tmperature) TSD(design target) A B Time Output stage on off on