EV4026-J-00B Universal Input, 20W Primary-side-control with Active PFC Offline WLED Driver Evaluation Board for PAR38 Bulb DESCRIPTION FEATURES The EV4026-J-00B 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-00B is typically designed for driving an isolated 20W PAR38 LED bulb with 40VTYP, 500mA LED load at universal input (90V-265VAC, 50/60Hz). The EV4026-J-00B 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 90 -265 40 500 20 VAC V mA W η 87~90 % 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 Short-circuit protection Over-temperature protection Fit inside PAR38 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. % EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 1 EV4026-J-00B– EVB DESCRIPTION EV4026-J-00B EVALUATION BOARD (L x W x H) 83.5mm x 30.0mm x 23mm Board Number MPS IC Number EV4026-J-00B MP4026GJ-Z EVALUATION BOARD SCHEMATIC Figure 1 - Schematic EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 2 EV4026-J-00B– EVB DESCRIPTION PCB LAYOUT (DOUBLE-SIDED) Figure 2 - Top Layer Figure 3 - Bottom Layer EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 3 EV4026-J-00B– EVB DESCRIPTION CIRCUIT DESCRIPTION The EV4026-J-00B 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, CX1, L1 ， L2, L3, L4, 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 to absorb the high ring voltage of surge test, L1, L2, CX1, L3, L4, R1, R2, R3 and C2 associated with CY1 form the EMI filter which can meet the requirement for universal input. The diode rectifier BD1 rectifies the input line voltage. Small bulk CBB capacitor C2 is used for a low impedance path for the primary switching current, to maintain high power factor, the capacitance of C2 should be selected with low value. R5, R6, R17, C4 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. R4, C3, D2, R15 are used to supply the power for MP4026. A 4.7μF electrolytic capacitor C3 is selected to maintain the supply voltage. At startup, C3 is first charged up by the starter resistor R4 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 R15, D2. R9, R10, D2, C1 are used to detect the auxiliary winding to get the transformer magnetizing current zero crossing signal for realizing the boundary conduction operation, and also monitor the output OVP condition. The OVP voltage is set by the divider ratio of R9, R10. D2 is used to block the negative plateau voltage of auxiliary winding when MOSFET is turn on. C1 is used to decouple the high frequency noise influence on CS/ZCD pin. R11, R12 are primary sensing resistors for primary side current control. The value of R11, R12 set the output LED current. R7 is used to form a feedforward from input line voltage to optimize the line regulation. C6, R14, D3 are used to damp the leakage inductance energy so the drain voltage can be suppressed at a safe level. Diode D1 rectifies the secondary winding voltage and the capacitor C7, C8 are the output filter. The resistor R13 is placed as pre-load to limit the output voltage rise too high in open load condition. EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 4 EV4026-J-00B– EVB DESCRIPTION EV4026-J-00B BILL OF MATERIALS Qty 1 Ref BD1 Value KBP206 1 C1 10pF 1 C2 220nF/630V 1 C3 4.7μF/50V 1 C4 5.6nF/50V 1 C5 1μF/16V 1 C6 10nF/630V 330μF/50V 1 1 1 1 1 C7, C8 CX1 CY1 D1 D2 D3 47nF/275VAC 1nF/4kV MURS340T3 BAV23A WSRGC10MH 1 D4 BZT52C30 1 1 1 F1 JP1 JR1 L1, L2, L3 250V/3.15A 0Ω 0Ω 1 L4 300μH 1 Q1 SMK0870F R1, R2 R3 R4 R5 R6, R14, R17 R7 R8 R9 R10 10kΩ 2 3 2 1 1 1 3 1 1 1 1 Package DIP Manufacturer Bangdayuan 0603 Murata DIP Panasonic ECQE6224KF DIP Jianghai CD287-50V4.7 0603 muRata GRM188R71H562KA01D 0805 Murata GRM21BR71C105KA01 1206 TDK DIP Jianghai CD263-50V330(10*16) DIP DIP SMC SOT-23 1206 Carli Hongke ON Semi Jianfu ZOWIE PX473K3IB29L270D9R JNK09E102MY02N MURS340T3 BAV23A WSRGC10MH SOD-123 Diodes BZT52C30 DIP COOPER SS-5-3.15A 1206 Yageo RC1206FR-070RL DIP Wurth 768772102 DIP EMEI TP4U300-00 TO-220F AUK SMK0870F Film Resistor;1% 1206 Yageo RC1206FR-0710KL 1kΩ 300kΩ 7.32kΩ Film Resistor;1% Film Resistor;5%,1W Film Resistor;1% 1206 DIP 0603 Yageo Any Yageo RC1206FR-071KL 499kΩ Film Resistor;1% 1206 Yageo RC1206FR-07499KL 1.6MΩ 51Ω 1.87kΩ 8.66kΩ Film Resistor;5% Film Resistor;5% Film Resistor;1% Film Resistor;1% 0603 0805 0603 0603 Yageo Yageo Yageo Yageo RC-03L165JT RC0805JR-0751RL RC0603FR-071k87L RC0603FR-078k66L 1mH Description BRIDGE, 600V, 2A Ceramic Capacitor, 50V, COG Capacitor;630V; CBB Electrolytic Capacitor; 50V;105℃ Ceramic Capacitor; 50V;X7R Ceramic Capacitor, 16V, X7R Ceramic Capacitor, 630V, X7R Electrolytic Capacitor; 50V;105℃ X2 Capacitor, 275V Y1 Capacitor, 4kV Diode, 3A, 400V Diode, 0.2A, 200V Diode, 1kV, 1A Zener Diode, 30V, 2mA Fuse, 250V, 3.15A Wire Film Resistor;1% Inductor, 1mH, 0.5A Common Choke, 300μH, 1A N-Channel MOSFET, 700V, 8A Manufactuer_P/N KBP206 GRM1885C1H100JAO1 C3216X7R2J103K RC0603FR-077K32L EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 5 EV4026-J-00B– EVB DESCRIPTION EV4026-J-00B BILL OF MATERIALS (continued) Qty 1 1 1 1 1 1 Ref R11 R12 R13 R15 R16 RV1 Value 1.1Ω 500mΩ 30kΩ 20Ω 1.5Ω TVR10431KSY 1 T1 FX0319 1 U1 MP4026 Description Film Resistor;1% Film Resistor;1% Film Resistor;1% Film Resistor;1% Film Resistor;1% 430V, 2500A EFD25;LP=950μH; NP:NS:NAUX:NShielding =81:27:17:60 Offline LED Lighting Controller Package 1206 1206 1206 1206 1206 DIP Manufacturer Yageo Yageo Yageo Yageo Yageo TKS Manufactuer_P/N RC1206FR-071R1L RC1206FR-070R5L RC1206FR-0730KL RC1206FR-0720RL RC1206FR-071R5L TVR10431KSY EFD25 EMEI FX0319 FCTSOT-6 MPS MP4026GJ-Z EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 6 EV4026-J-00B– EVB DESCRIPTION TRANSFORMER SPECIFICATION Electrical Diagram 1 3 N5 N1 W 2 4 N3 B N2 5 Sec. Side Float WINDING START N4 4 Pri. Side Figure 4 – Transformer Electrical Diagram Notes: 1. N4 is shielding winding, float Float pin in the winding. Winding Diagram 3Ts 1T N5 N4 1T N3 1T N2 1T N1 Figure 5 – Winding Diagram Winding Order Winding No. N1 N2 N3 N4 N5 Tape Layer Number 1 1 1 1 3 Start & End 2→3 5→4 W→B 4→Float 3→1 Magnet WireΦ(mm) 0.25*2 0.18*1 0.35*2 (T.I.W) 0.15*1 0.25*2 EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. Turns 57 17 27 60 24 7 EV4026-J-00B– EVB DESCRIPTION Electrical Specifications Electrical Strength Primary Inductance Primary Leakage Inductance 1 second, 50Hz, from Pins 1, 2, 4, 5 to W, B Pins 1- 2, all other windings open, measured at 40kHz, 0.25 VRMS Pins 1-2 with pins 4, 5 W, B shorted, measured at 100kHz, 0.1 VRMS 2500VAC 950μH±8% 20μH±10% Materials Item 1 2 3 4 5 6 7 8 9 Description 2 Core: EFD25, UI=2300, AL=179.0nH/N ±3% GAPPED, ACME P4 Bobbin: EFD25, 5+5PIN SECT T-H T375J UL94V-0 Wire: Φ0.25mm, Φ0.18mm, Φ0.15mm, UEWF, CLASS B Triple Insulation Wire: Φ0.35mm,TRW(B) Tape: 17.0mm(W)×0.06mm(TH), Yellow Tube:#22 Black Varnish: BC-346A Epoxy: E-500 Solder Bar: SN99.5/Cu0.5 EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 8 EV4026-J-00B– EVB DESCRIPTION EVB TEST RESULTS Performance Data f (Hz) 60 50 VIN (VAC) 90 100 110 120 135 150 170 185 200 220 230 240 250 265 PIN (W) 22.08 21.92 21.82 21.74 21.66 21.63 21.61 21.64 21.68 21.74 21.77 21.81 21.86 21.95 VOUT (V) 39.40 39.40 39.40 39.40 39.40 39.40 39.40 39.40 39.40 39.40 39.40 39.40 39.40 39.40 I12LEDs (mA) 489.0 490.0 491.0 492.0 492.0 492.0 492.0 492.0 492.0 492.0 492.0 492.0 492.0 493.0 POUT (W) 19.27 19.31 19.35 19.38 19.38 19.38 19.38 19.38 19.38 19.38 19.38 19.38 19.38 19.42 η (%) 87.3 88.1 88.7 89.2 89.5 89.6 89.7 89.6 89.4 89.2 89.0 88.9 88.7 88.5 PF 0.997 0.997 0.996 0.995 0.993 0.989 0.983 0.978 0.972 0.962 0.956 0.950 0.943 0.933 I11LEDs (mA) 493 494 494 494 494 494 494 495 495 495 495 495 495 495 I10LEDs (mA) 496 497 497 497 498 498 498 498 498 498 498 498 498 499 I9LEDs (mA) 499 500 500 500 500 500 500 501 501 501 501 501 502 502 I8LEDs (mA) 502 502 503 503 503 504 504 504 504 504 505 505 505 506 I7LEDs (mA) 506 506 506 506 506 506 506 507 507 507 508 508 508 508 I6LEDs (mA) 509 510 510 509 509 509 508 508 508 508 508 508 508 508 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 20.52 179.61 230/50 20.42 93.44 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 39 139.54 77.98 41.04 20.52 14.36 12.15 10.53 9.29 8.32 7.52 6.87 6.32 5.85 5.45 5.10 4.79 4.51 4.27 4.05 16.21 2.47 1.07 1.40 1.39 1.33 1.20 1.07 1.03 0.87 0.80 0.69 0.59 0.47 0.37 0.36 0.29 0.25 0.16 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 69.43 38.80 20.42 10.21 7.15 6.05 5.24 4.62 4.14 3.74 3.42 3.14 2.91 2.71 2.54 2.38 2.25 2.12 2.02 14.83 3.68 1.65 1.29 1.08 1.09 0.89 0.85 0.79 0.76 0.64 0.54 0.55 0.47 0.40 0.33 0.31 0.24 0.26 16.65 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-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 9 EV4026-J-00B– 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-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 10 EV4026-J-00B– EVB DESCRIPTION EVB TEST RESULTS Performance waveforms are tested on the evaluation board. 12 LEDs in series, ILED=500mA, VOUT=40V, LP=950μH, NP:NS:NAUX =81:27:17. EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 11 EV4026-J-00B– EVB DESCRIPTION EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. 12 LEDs in series, VIN=120VAC/60Hz, ILED=500mA, VOUT=40V, LP=950μH, Np:NS:NAUX =81:27:17. EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 12 EV4026-J-00B– EVB DESCRIPTION EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. 12 LEDs in series, VIN=230VAC/50Hz, ILED=500mA, VOUT=40V, LP=950μH, Np:NS:NAUX =81:27:17. EV4026-J-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 13 EV4026-J-00B– 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-00B Rev.1.0 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 14