EV44011HS+4689DN-00A Flyback PFC+2 Channel DC/DC 30W Offline WLED Driver DESCRIPTION FEATURES The EV44011HS+4689DN-00A is an evaluation board of MP44011 and MP4689 for 30W LED lighting driver. The EV44011HS+4689DN-00A contains 2 stages: the first stage is Flyback PFC using MP44011; the second stage is 2-channel DC/DC using MP4689 and every channel can deliver 15W/350mA for LED. MP44011 is a boundary conduction mode PFC controller with internal harmonic injection comparing with MP44010 which is a traditional Boundary mode PFC controller, MP44011 can bring benefits, such as decreased output cap of Flyback PFC and reduced transformer core size. (Please see details in MP44011 datasheet.) MP4689 is a high voltage step-down switching regulator to deliver a constant current to LED. The hysteresis current mode control is applied for very fast response. The EV44011HS+4689DN-00A can meet the EN55015 standard. Very Small Output Cap Reduced Transformer Core Size 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 APPLICATIONS Commercial LED lighting Automotive and Industry lighting Other LED 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. ELECTRICAL SPECIFICATIONS Parameter Symbol Value Units Input AC Voltage VAC 85 to 265 V Output current / Channel IOUT 350 mA Output Power POUT 30 W EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 1 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER EVALUATION BOARD EV44011HS+4689DN-00A EVALUATION BOARD (L x W x H) (15cm x 3cm x 2.78cm) Board Number MPS IC Number MP44011HS EV44011HS+4689DN-00A MP4689DN EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 2 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER EVALUATION BOARD EVALUATION BOARD SCHEMATIC EV44011HS+4689DN-00A BILL OF MATERIALS Qty Ref Value Description 1 1 1 1 C1 C2 C3 C4 0.22μF 10nF 10μF 2.2μF 0 C5, C11 C22, C27 NS 5 1 C6, C21, C24 C25, C28 C7 Package Manufacturer Part Number CBB Cap.,630V Ceramic Cap., 50V, X7R Ceramic Cap., 50V, X7R Ceramic Cap., 10V, X7R DIP 0603 1210 0603 Panasonic muRata JiangHai muRata ECQE6224KF GRM188R71H103KA01D GRM32DR71E106KA12 GRM188R71A225KE15D 0.1μF Ceramic Cap., 50V, X7R 0603 muRata GRM188R71H104KA93D 4.7nF Y Cap., 2600V DIP HongKe JYK12F472MY72N 10nF 220pF 47μF 22μF 2.2μF Ceramic Cap., 630V, X7R Ceramic Cap., 1000V, X7R Electroytic Cap., 100V Ceramic Cap., 25V, X5R Ceramic Cap., 16V, X5R 1206 1206 DIP 1210 0805 TDK muRata JiangHai muRata muRata C3216X7R2J103K GRM31A7U3A221JW31D CD263-100V47 GRM32ER61E226KE15L GRM21BR61C225KA88L 2.2μF Ceramic Cap., 100V, X7R 1210 muRata GRM32ER72A225KA35L 2 C8 C9, C10 C12 C13, 14, C15 C16 C17, C18 C19, C20 C22, C26 15nF Ceramic Cap., 50V, X7R 0603 TDK 3 1 3 1 1 1 CX1, CX2 CX3 D1 D2, D5, D7 D3 D4 D6 0.1μF X Cap.,275V Diode, 5mA, 18V Diode, 0.15A, 75V TVS, 1mA, 300V Diode, 1A, 1000V Diode, 3A, 400V DIP SOD-123 SOD-123 Do-15 DIP SOD-123 KaiLi Diodes Diodes Brighting Diodes Diodes 1 D8 Diode, 5mA, 10V SOD-123 Diodes 1 2 1 3 1 4 C1608X7R1H153K PX104K3ID19L270D9R BZT52C18 1N4148W P6KE350A 1N4007 UF3004 BZT52C10 EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 3 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER EVALUATION BOARD EV44011HS+4689DN-00A BILL OF MATERIALS (continued) Qty Ref 1 Value Description Package D9 Diode, 2mA, 20V SOD-123 Diodes BZT52C20 2 2 1 3 1 1 1 D10, D11 D12, D13 BR1 L1, L2, Ldm1 Lcm1 Lcm2 VAR1 Diode, 2mA, 30V Diode, 1A, 100V Diode, 600V, 4A Diodes Diodes Diodes BZT52C30 B1100 GBU406 1mH 47μH 32mH 470V SOD-123 SMA DIP DIP DIP DIP DIP Wurth 744841247 Jingdian TVR14471KS42Y 2 1 1 1 1 2 R1, R2 R3 R4 R5 R6 R7, R21 1MΩ 2MΩ 13.3kΩ 499kΩ 20Ω 1.24kΩ Film Res., 1% 5% Film Res., 1% Film Res., 1% Film Res., 5% Film Res., 1% 1206 DIP 0603 1206 1206 0603 Yageo any Yageo Panasonic Royalohm Yageo RC1206FR-071ML 1 1 1 3 1 2 R8 R9 R10 R11,R25,R26 R12 R13, R14 20kΩ 62kΩ 56kΩ 0Ω 68kΩ 300kΩ Film Res., 1% Film Res., 1% Film Res., 1% Film Res., 5% Film Res., 1% 5%, 1W 0603 0603 0603 0805 0603 DIP Royalohm Yageo Yageo Royalohm Yageo Any 0603F2002T5E RC0603FR-0762KL RC0603FR-0756KL 0805S8J0000T5E RC0603FR-0768KL 2 2 1 1 1 3 1 R15, R16 R17, R18 R19 R20 R22 R23, R30,R34 R24 5.1Ω 0.2Ω 499Ω 2.37kΩ 1kΩ 10kΩ 270kΩ Film Res., 5% Film Res., 1% Film Res., 1% Film Res., 1% Film Res., 1% Film Res., 1% Film Res., 1% 1206 0805 0603 0603 0603 0603 0603 Yageo Yageo Yange Yageo Royalohm Yageo Yageo RC1206JR-075R1L RL0805FR-070R2L RC0603FR-07499RL RC0603FR-072K37L 0603F1001T5E RC0603FR-0710KL RC0603FR-07270KL 2 2 2 2 1 1 R27 R28, R32 R29, R33 R31, R35 Q1 Q2 300Ω 280kΩ 0.56Ω 0Ω Film Res., 1% Film Res., 1% Film Res., 1% Film Res., 5% MOSFET, 8A, 800V Transistor, 0.5V, 25V 0603 0603 0805 0603 TO-220 SOT-23 Yageo Yageo Yageo Royalohm RC0603FR-07300RL RC0603FR-07280KL RL0805FR-070R56L 0603J0000T5E FQPF8N80C S8050 1 F1 1A 1 1 1 1 2 T1 U1 U2 U3 U4, U5 250V EE25, 110:36:6:8 Photocoupler BCM PFC Controller 2.5V Step-Down Regulator Manufacturer Part Number DIP COOPER Bussmann SMD SO-8 SOT-23 SO-8 Sharp MPS Changdian MPS RC0603FR-0713K3L ERJ8ENF4993V 1206J0200T5E RC0603FR-071K24L SS-5-1A FX0209 PC817B MP44011HS CJ431 MP4689DN EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 4 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER EVALUATION BOARD EVB TEST RESULTS Performance waveforms are tested on the evaluation board. VAC=85V-265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.0mH, N1:N2:N3:N4=110:36:6:8. EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 5 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER EVALUATION BOARD EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. VAC=85V-265V, 14 LEDs in series for each channel, IOUT1= IOUT2=350mA, POUT=30W, Lp=1.0mH, N1:N2:N3:N4=110:36:6:8. EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 6 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER 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=1.0mH, N1:N2:N3:N4=110:36:6:8. EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 7 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER EVALUATION BOARD PRINTED CIRCUIT BOARD LAYOUT Figure 1—Top Silk Layer Figure 2—Bottom Silk Layer Figure 3—Bottom Layer EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 8 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER 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. EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 9 EV44011HS+4689DN-00A – BOUNDARY MODE PFC CONTROLER EVALUATION BOARD APPENDIX: TRANSFORMER SPECIFICATION Electrical Diagram Primary Winding Winding Diagram Secondary Winding Tapes:3T 1 8 N1 N5 N2 NS Tapes:3T 6 N5 N4 6 3 2 Tapes:1T N3 5 Auxiliary Winding N4 4 N3 Tapes:1T Winding Start Teflon Tube Auxiliary Winding N2 Pin Definition of Bobbin Tapes:3T Pin out 1 N1 Tapes:1T 8 Table 1. Electrical Characteristic 2 Parameter Primary Inductance 7 3 6 4 5 Value Lp(4-1) 1.0mH±5% Core EE25 Bobbin EE25 Core Material 3C85 or equivalent Turn Ratio View from the top Condition N1:N2:N3:N4:N5 55:36:6:8:55 Table 2. Winding Specification Tape Turns 3 1 1 1 3 Winding No. N1 N2 N3 N4 N5 Start& End 3→NS 8→6 5→6 2→4 NS→1 Wire Diameter (mm) 0.3×1 0.3×2 0.18×1 0.18×1 0.3×1 Turns 55 36 6 8 55 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. EV44011HS+4689DN-00A Rev. 1.1 www.MonolithicPower.com 11/13/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 10