EV44010HS+4688DN-00A BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD Evaluation Board Report 30W AC-DC LED Lighting Driver with PFC Design Specs Input Voltage Output Current Output Power Isolation MPS IC Value 85-265 350 30 Unit VAC mA/channel W Yes MP44010HS, MP4688DN AC-DC LED lighting AC-DC Constant Current Power Supply Application Document Number EBXXX Author Application Engineering Department Date Nov, 2014 Revision 1.0 Design Summary EV44010HS+4688DN-00A evaluation board provides a reference design for a universal offline isolated LED power supply that can provide two channel outputs, each channel can provide 350mA/15W to drive LEDs. For this design the MP44010HS is used as flyback and PFC controller, and two MP4688DNs are used to regulate constant current output for each channel. The design contains the complete specification of the power supply, a detailed circuit diagram, the entire bill of materials required to build the power supply, drawing of the power inductors and transformers, and test data of the most important performance. EV44010-S+HR1000-S-01B Rev. 1.0 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 1 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD DESCRIPTION ELECTRICAL SPECIFICATIONS The EV44010HS+4688DN-00A is an evaluation board of MP44010 and MP4688 for 30W LED lighting driver. Parameter The EV44010HS+4688DN-00A contains 2 stages: the first stage is flyback PFC using MP44010 which can provide high power factor; the second stage is 2-channel DC/DC using MP4688 and every channel can deliver 15W/350mA for LED. MP44010 is a boundary conduction mode PFC controller which can provide simple and high performance active power factor correction using minimum external components. MP4688 is a high voltage input step-down switching regulator to deliver a constant current to LED. The hysteresis current mode control is applied to reach very fast response. The EV44010HS+4688DN-00A can meet the Class C standard of IEC61000-3-2 and EN55015 standard. Symbol Value Units Input AC Voltage VAC 85 to 265 VAC Output current / Channel IOUT 350 mA Output Power POUT 30 W FEATURES Wide Operating Input Range(from 85V to 265VAC) Meet Class C Standard of IEC61000-3-2 Meet EN55015 Standard Boundary Conduction Mode for PFC Stage Hysteresis Current Mode Control for DC/DC Stage ±5% LED Current Accuracy Up to 20kHz PWM Dimming Frequency Dedicated PWM Dimming Control Input Output Short Circuit Protection 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. EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 2 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD EV44010HS+4688DN-00A EVALUATION BOARD (L x W x H) (15cm x 3cm x 2.78cm) Board Number EV44010HS+4688DN-00A MPS IC Number MP44010HS MP4688DN EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 3 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD EVALUATION BOARD SCHEMATIC R27 280kΩ C7 4.7nF D5 R23 UF3004 0Ω T1 R5 499kΩ 1mH R6 D2 20Ω 1N4148 BR1 0.22μF R3 C8 10nF N1 N2 PC817 N3 N4 2.2nF R9 Lcm1 32mH C4 220nF CX1 C3 22μF C2 R4 13.3kΩ D1 BZT52C18 R8 30.1kΩ R10 10kΩ R7 1.24kΩ 10kΩ FB 0.1μF VAR1 COMP GATE MULT GND CS F1 U2 5.1Ω 5.1Ω R16 R11 C5 NS R17 0.2Ω D10 B190 280kΩ LED2- GND N/C C19 10kΩ 2.2μF 10kΩ SW MP4688 C23 0.1μF EN2 R34 DIM NS 0Ω LED2+ C21 15nF EN VIN U5 C22 NS 0.56Ω FB C13 2.2μF L1 1mH 0.1μF R32 C20 2.2μF 0.2Ω NS 0.1μF BST R22 R30 R33 R21 U3 CJ431 SW R31 R20 2.37kΩ Q1 FQPF8N80C BST C25 0Ω PC817 DIM LED1+ EN1 EN VIN C16 C18 NS C17 15nF U4 MP4688 C15 2.2μF R26 U1 ZCS 2.2μF 1kΩ 1kΩ MP44010 AC Input R19 1N4148 R15 R25 300Ω D7 BZT52C10 VIN R14 C14 Q2 S8050 R18 499Ω GND N/C R24 249kΩ 10kΩ 0.56Ω FB C12 22μF C11 22μF 1N4148 R12 68kΩ D3 C10 22μF D6 FB1 742792141 C6 0.1μF R28 D9 BZT52C30 FR107 D4 R2 NS R1 NS D8 BZT52C30 330uF C9 2MΩ C1 220nF CX2 R13 300kΩ LED1- 0.1μF R29 GBU406 Ldm1 C24 L2 1mH D11 B190 EV44010HS+4688DN-00A BILL OF MATERIALS Qty 1 1 1 1 0 Ref Value Description Package Manufacturer Part Number C1 0.22μF CBB Cap.,630V C2 2.2nF Ceramic Cap., 50V, X7R C3 22μF Electrolytic Cap., 50V C4 220nF Ceramic Cap., 16V, X7R C5, C18, C22 NS C6,C16,C23, 0.1μF Ceramic Cap., 50V, X7R C24,C25 C7 4.7nF Y Cap., 2600V DIP 0603 DIP 0603 Panasonic Murata JiangHai Murata ECQE6224KF GRM188R71H222KA01D CD281L-50V22 GRM188R71C224KA93D 0603 Murata GRM188R71H104KA93D DIP HongKe JYK12F472MY72N Ceramic Cap., 630V, X7R Electrolytic Cap., 100V Ceramic Cap., 25V, X5R Ceramic Cap., 16V, X5R 1206 DIP 1210 0805 TDK JiangHai Murata Murata C3216X7R2J103K CD263-100V330 GRM32ER61E226KE15L GRM21BR61C225KA88L 2.2μF Ceramic Cap., 100V, X7R 1210 Murata GRM32ER72A225KA35L 2 1 C8 C9 C10, C11, C12 C13 C14, 15, C19, C20 C17,C21 CX1 15nF Ceramic Cap., 50V, X7R 0.1μF X Cap.,275V 0603 DIP TDK KaiLi C1608X7R1H153K PX104K3ID19L270D9R 1 1 3 1 1 CX2 D1 D2, D3, D6 D4 D5 DIP SOD-123 SOD-123 DIP DIP KaiLi Diodes Diodes Diodes Diodes PX224K3ID49L270D9R BZT52C18 1N4148W FR107 UF3004 5 1 1 1 3 1 4 10nF 330μF 22μF 2.2μF 0.22μF X Cap.,275V Diode, 5mA, 18V Diode, 0.15A, 75V Diode, 1A, 1000V Diode, 3A, 400V EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 4 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD EV44010HS+4688DN-00A BILL OF MATERIALS (continued) Qty Ref Value Description Package Manufacturer Part Number 1 D7 Diode, 5mA, 10V SOD-123 Diodes BZT52C10 2 2 1 3 1 1 D8, D9 D10, D11 BR1 L1, L2, Ldm1 Lcm1 VAR1 Diode, 2mA, 30V Diode, 1A, 90V Diode, 600V, 4A SOD-123 SMA DIP DIP DIP DIP Diodes Diodes Diodes BZT52C30 B190A GBU406 Jingdian 0 R1, R2, R30, R34 NS 1 1 1 1 1 1 R3 R4 R5 R6 R11 R7 2MΩ 13.3kΩ 499kΩ 20Ω 0Ω 1.24kΩ Film Res., 5% Film Res., 1% Film Res., 1% Film Res., 5% Film Res., 5% Film Res., 1% DIP 0603 1206 1206 1206 0603 Any Yageo Panasonic Royalohm Yageo Yageo RC0603FR-0713K3L ERJ8ENF4993V 1206J0200T5E RC1206JR-070RL RC0603FR-071K24L 1 30.1kΩ Film Res., 1% 0603 Yageo RC0603FR-0730K1L 1 R9 R8, R10, R22, R29, R33 R12 1 2 2 1 2 1 R13 R14, R15 R16, R17 R18 R19, R21 R20 2 1 1 2 2 1 R23, R26 R24 R25 R27, R31 R28, R32 FB1 1 1 Q1 Q2 1 F1 1 1 1 1 2 T1 U1 U2 U3 U4, U5 5 1mH 32mH 470V TVR14471KS42Y 10kΩ Film Res., 1% 0603 Yageo RC0603FR-0710KL 68kΩ Film Res., 1% 0603 Yageo RC0603FR-0768KL 300kΩ 5.1Ω 0.2Ω 499Ω 1kΩ 2.37kΩ Film Res., 1%, 1W Film Res., 5% Film Res., 1% Film Res., 1% Film Res., 1% Film Res., 1% DIP 1206 0805 0603 0603 0603 Any Yageo RC1206JR-075R1L Yange Royalohm Yageo RC0603FR-07499RL 0603F1001T5E RC0603FR-072K37L 0Ω 249kΩ 300Ω 280kΩ 0.56Ω Film Res., 5% Film Res., 1% Film Res., 1% Film Res., 1% Film Res., 1% Magnetic Bead 0603 0603 0603 0603 0805 1206 Royalohm Yageo Yageo Yageo Yageo Wurth 0603J0000T5E RC0603FR-07249KL RC0603FR-07300RL RC0603FR-07280KL RL0805FR-070R56L 742792141 MOSFET, 8A, 800V Transistor, 0.5V, 25V 1A 250V EF25, 100:33:8:9 Photocoupler BCM PFC Controller 2.5V Step-Down Regulator TO-220 SOT-23 DIP SMD SO-8 SOT-23 SO-8 FQPF8N80C S8050 COOPER Bussmann Sharp MPS Changdian MPS SS-5-1A FX0148 PC817B MP44010HS CJ431 MP4688DN EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 5 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VAC=85V to 265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.15mH, N1:N2:N3:N4=100:33:8:9. EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 6 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VAC=85V to 265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.15mH, N1:N2:N3:N4=100:33:8:9. EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 7 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VAC=85V to 265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.15mH, N1:N2:N3:N4=100:33:8:9. EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 8 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD PRINTED CIRCUIT BOARD LAYOUT Figure 1—Top Silk Layer Figure 2—Bottom Silk Layer Figure 3—Bottom Layer EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 9 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD QUICK START GUIDE 1. Preset AC input voltage between 85V and 265V. Then turn off AC power supply. 2. Connect the LED string to the LED+ and LED- pins on each channel. 3. Connect the Line and Neutral terminals of the power supply output to AC input. 4. Turn the power supply on. The board will automatically startup. Contact Information To request this evaluation board, please refer to your local sales offices which can be found from: http://www.monolithicpower.com/Company/Contact-Us Disclaimer Monolithic Power Systems (MPS) reserves the right to make changes to its products and to discontinue products without notice. The applications information, schematic diagrams, and other reference information included herein is provided as a design aid only and are therefore provided as-is. MPS makes no warranties with respect to this information and disclaims any implied warranties of merchantability or non-infringement of third-party intellectual property rights. MPS cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a MPS product. No circuit patent licenses are implied. Certain applications using semiconductor products may involve potential risks of death, personal injury, or severe property or environmental damage (“Critical Applications”). MPS PRODUCTS ARE NOT DESIGNED, INTENDED, AUTHORIZED, OR WARRANTED TO BE SUITABLE FOR USE IN LIFE‑SUPPORT APPLICATIONS, DEVICES OR SYSTEMS, OR OTHER CRITICALAPPLICATIONS. Inclusion of MPS products in critical applications is understood to be fully at the risk of the customer. Questions concerning potential risk applications should be directed to MPS. MPS semiconductors are typically used in power supplies in which high voltages are present during operation. High voltage safety precautions should be observed in design and operation to minimize the chance of injury. EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 10 EV44010HS+4688DN-00A – BOUNDARY MODE PFC CONTROLLER EVALUATION BOARD APPENDIX: TRANSFORMER SPECIFICATION Electrical Diagram Primary Winding Winding Diagram Secondary Winding Margin Tapes 1 Margin Tapes 10 N1 Tapes:3T N2 NS N5 8 N5 Tapes:3T 8 4 3 N4 N3 Tapes:1T 6 N4 Auxiliary Winding 5 N3 Winding Start Teflon Tube Auxiliary Winding Tapes:1T N2 Pin Definition of Bobbin Tapes:3T Pin out N1 1 10 2 9 Tapes:1T Table 1. Electrical Characteristic 3 8 Parameter Primary Inductance 4 7 Core EF25 Bobbin EF25 Core Material 3C85 or equivalent 5 6 Turn Ratio View from the top Condition Value Lp(4-1) 1.15mH±5% N1:N2:N3:N4:N5 50:33:8:9:50 Table 2. Winding Specification Tape Turns 3 1 1 1 3 Winding No. N1 N2 N3 N4 N5 Margin Tapes 2mm 2mm 2mm 2mm 2mm Start& End 4→NS 10→8 6→8 3→5 NS→1 Wire Diameter (mm) 0.33×1 0.33×2 0.18×1 0.18×1 0.33×1 Turns 50 33 8 9 50 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. EV44010HS+4688DN-00A Rev. 1.1 www.MonolithicPower.com 10/16/2015 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2015 MPS. All Rights Reserved. 11