Using LV5011MD in 120VAC, 6W Buck

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
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1. Introduction
2. Features
3. Performance Specifications
3.1. Application constitution
3.2. Electrical characteristics
4. Schematic
5. Evaluation Board
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6. Test Setup
7. Test Procedure
7.1 Line/Load Regulation and Efficiency Measurement Procedure
7.2 Equipment Shutdown
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7.3 Phase Angle Decode vs LED Current (at dimming)
8. Performance Data
8.1 Efficiency
8.2 Power factor
8.3 Line regulation
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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
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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 = 25C)
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