EV4026-J-00C Universal Input, 18W Primary-side-control with Active PFC Isolated T8 LED Lamp Driver Evaluation Board The Future of Analog IC Technology DESCRIPTION FEATURES The EV4026-J-00C 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-00C is typically designed for driving an isolated 18W T8 LED lamp with 36VTYP, 500mA LED load at universal input (90V-265VAC, 50/60Hz). The EV4026-J-00C 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 η 90-264 36 500 18 84~86 VAC V mA W % 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(OVP) Short-circuit protection(SCP) Primary-side over-current protection(OCP) Over-temperature protection(OTP) Fit inside T8 tube enclosure APPLICATIONS • • • • T8 Tube Replacement 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-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 1 EV4026-J-00C– EVB DESCRIPTION EV4026-J-00C EVALUATION BOARD (L x W x H) 238mm x 18mm x 10mm Board Number MPS IC Number EV4026-J-00C MP4026GJ-Z EVALUATION BOARD SCHEMATIC T1 EDR2609 Lp=740uH Np:Nsec:Naux=40:10:7 R1 R15 680k/1206 5.1k/1206 1 2 R13 NS 1 C6 10nF/630V/1206 1 2 6 1 2 3 1 4 CX1 100nF/275Vac 1 4 LED+ 2 MURS320T3 200V/3A/SMC 3 D3 1N4007 2 2 D4 R16 680k/1206 2 C1 220nF/450V 1 C7 NS 1 L3 2.2mH R14 30k/1206 C8 330uF/50V 8 BD1 DF06S C9 330uF/50V 36V/500mA L4 600uH LED- 5 R2 300k/1W R3 499k/1%/1206 L5 Bead/742792063 2 CY1 1 D2 BAV23A/SOT-23 1 1 L2 60mH 2 2.2nF/4000V 3 R7 R6 R5 20/1206 2 845k/1% L1 1.2mH 1 D1 BZT52C27 2 N 90VAC-264VAC 6 2 MULT CS/ZCD R8 20/0805 COMP GND C5 10pF/50V 3 C4 1uF/10V 0805 1 Q1 SMK0870F 700V/8A 5 R4 8.2k/1% 1 L GATE R9 1k/1% 1 F1 250V/2A C3 2.2nF/50V VCC 3 1 TVR10431 4.87k/1% U1 MP4026 R17 499k/1%/1206 2 2 C10 6.8uF/50V 2 RV1 C2 0.1uF/50V 4 R10 0.5/1%/1206 R11 1.1/1%/1206 R12 1.1/1%/1206 Figure 1 - Schematic EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 2 EV4026-J-00C– EVB DESCRIPTION PCB LAYOUT (DOUBLE-SIDED) Figure 2 - Top Layer Figure 3 - Bottom Layer EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 3 EV4026-J-00C– EVB DESCRIPTION CIRCUIT DESCRIPTION The EV4026-J-00C 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, L1, L2, L3, R1, CX1, C1 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, R1 and C1 associated with L4, CY1 form the EMI filter which can meet the requirement for universal input. The bridge rectifier BD1 rectifies the input line voltage. Small bulk CBB capacitor C1 is used for a low impedance path for the primary switching current, to maintain high power factor, the capacitance of C1 should be selected with low value. R3, R4, R17, C3 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. R2, R5, C2, C10, D2 are used to supply the power for MP4026. A 6.8μF electrolytic capacitor C10 is selected to maintain the supply voltage. At start-up, C10 is first charged up by the starter resistor R2 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 R5, D2. R7, R9, D2, C5 are used to detect the auxiliary winding to get the transformer magnetizing current zero crossing signal for realizing the valley switching operation, and also monitor the output OVP condition. The OVP voltage is set by the divider ratio of R7, R9. D2 is used to block the negative plateau voltage of auxiliary winding when MOSFET is turn on. C5 is used to decouple the high frequency noise influence on CS/ZCD pin. R10, R11, R12 are primary sensing resistors for primary side current control. The value of R10, R11 and R12 set the output LED current. R6 is used to form a feedforward from input line voltage to optimize the line regulation. C6, R15, R16, D3 are used to damp the leakage inductance energy so the drain voltage can be suppressed at a safe level. Diode D4 rectifies the secondary winding voltage and the capacitor C8, C9 are the output filter. The resistor R14 is placed as pre-load to limit the output voltage rise too high in open load condition. EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 4 EV4026-J-00C– EVB DESCRIPTION EV4026-J-00C BILL OF MATERIALS Qty Ref Value Description Rectifier Bridge, 600V, 1A Package Manufacture Manufacturer_PN SMD SEP DF06S DIP Carli TF224K2Y109L270D9R 0603 Murata GRM188R71H104KA93D 0603 Murata GRM188R71H222KA01D 0805 Murata GRM21BR71A105KA01L 0603 Murata GRM1885C1H100JA01 1206 Murata GRM31BR72J103KW01L DIP Jianghai CD263-50V330 DIP Sancon CF120302-5 DIP Carli PX104K3ID19L270D9R Hongke JN12E222MY02N Diodes BZT52C27 BAV23A-7 1N4007 MURS320T3 1 BD1 DF06S 1 C1 220nF/450V 1 C2 100nF/50V 1 C3 2.2nF/50V 1 C4 1μF/10V 1 C5 10pF/50V 1 C6 10nF/630V 1 C7 C8, C9 NS 1 C10 6.8μF/50V 1 CX1 100nF/275V 1 CY1 2.2nF/4000V Electrolytic Capacitor, 50V Electrolytic Capacitor, 50V Film Capacitor, X2, 275V Y1 Capacitor, 4000V 1 D1 BZT52C27 Zener Diode, 27V 1 1 1 D2 D3 D4 BAV23A 1N4007 MURS320T3 Diode, 0.2A, 200V Diode, 1A, 1000V Diode, 3A, 200V DIP SOD123 SOT-23 DO-41 SMC 1 F1 250V/2A Fuse DIP 1 1 1 1 L1 L2 L3 L4 1.2mH 60mH 2.2mH 600μH DIP DIP DIP DIP 1 L5 742792063 Common Inductor Common Inductor Inductor, 2.2mH, 0.5A Common Inductor EMI Suppression Ferrite Bead Diodes Diodes ON Semi COOPER BUSSMANN Emei OEMA OEMA Emei 0805 Wurth 742792063 1 Q1 SMK0870F TO220F-3L AUK SMK0870F 1 R1 5.1kΩ 1206 LIZ CR06T05NJ5K1 1 R2 R3, R17 300kΩ DIP Any Any 1206 Yageo RC1206FR-07499KL 1 R4 8.2kΩ 0603 Yageo RC0603FR-078K2L 1 R5 20Ω 1206 Yageo RC1206JR-0720RL 1 R6 845kΩ 0603 Yageo RC0603FR-07845KL 1 R7 4.87kΩ 0603 Yageo RC0603FR-074K87L 1 R8 20Ω 0805 Yageo RC0805JR-0720RL 2 2 330μF/50V 499kΩ CBB, 450V Ceramic Cap, 50V, X7R Ceramic Cap, 50V, X7R Ceramic Cap, 10V, X7R Ceramic Cap, 50V, COG Ceramic Cap, 630V, X7R N-MOS, 8A, 700V Thick Film Chip RES, 5% Metal Film RES, 1W Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 5% Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 5% SS-5-2A TP4M1.2-02 TP4U300-00 EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 5 EV4026-J-00C– EVB DESCRIPTION EV4026-J-00C BILL OF MATERIALS (continued) Qty Ref Value 1 R9 1kΩ 1 R10 500mΩ 1 R11, R12 R13 NS 1 R14 30kΩ 2 1.1Ω 1 R15, R16 RV1 430V/2500A 1 T1 FX0327 1 U1 MP4026 2 680kΩ Description Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 1% Thick Film Chip RES, 1% Zinc Oxide Varistor EDR2609, Lp=740μH, Np:Ns:Naux=40:10:7 LED Lighting Controller Package Manufacturer Manufacturer_P/N 0603 Yageo RC0603FR-071KL 1206 Yageo RC1206FR-070R5L 1206 Yageo RC1206FR-071R1L 1206 Yageo RC1206FR-0730KL 1206 Yageo RC1206FR-07680KL DIP TKS TVR10431KSY EDR2609 Emei EDR26P8U740-00 FCTSOT-6 MPS MP4026GJ-Z R0 EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 6 EV4026-J-00C– EVB DESCRIPTION TRANSFORMER SPECIFICATION Electrical Diagram 1 6 N1 N3 8 3 4 Sec. Side N2 5 4 Copper foil WINDING START TFL TUBE Pri. Side Figure 4 – Transformer Electrical Diagram Notes: Wind copper foil (3.0mm x 0.025mm) to circle the side of transformer and connect to PIN4 Winding Diagram 1T N3 1T N2 1T N1 Figure 5 – Winding Diagram Winding Order Winding No. N1 N2 N3 Tape Layer Number 1 1 1 Start & End 3→1 5→4 6→8 Magnet WireΦ(mm) 0.3*1 0.18*1 0.4*1 (T.I.W) EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. Turns 40 7 10 7 EV4026-J-00C– EVB DESCRIPTION Electrical Specifications Electrical Strength 1 second, 50Hz, from Pins 1, 3, 4, 5 to 6, 8 Primary Inductance Pins 1-3, all other windings open, measured at 10kHz, 0.1 VRMS 3500VAC 740μH±10% Materials Item 1 2 3 4 5 6 7 8 9 10 Description 2 Core: EDR2609, UI=2300±25%, AL=462.5nH/N ±3% GAPPED, PC4 Bobbin: EDR26 T-H, 8PINS, 1SEC, T375J, PINL=4.0±0.2mm Wire: Φ0.18mm, Φ0.20mm, Φ0.30mm, 2UEW, CLASS F Triple Insulation Wire: Φ0.40mm,TRW(B) Tape: 4.0mm(W)×0.06mm(TH), Yellow; 5.0mm(W)×0.06mm(TH), Yellow Copper foil: 3.0mm(W)×0.025mm(TH) Tube:AWG#23 CLEAR; AWG#30 CLEAR Varnish: BC-346A Epoxy: E-500 Solder Bar: SN99.5/Cu0.5 EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 8 EV4026-J-00C– EVB DESCRIPTION EVB TEST RESULTS Performance Data f (Hz) 60 50 VIN (VAC) PIN (W) VOUT (V) I12LEDs (mA) POUT (W) η (%) PF I11LEDs (mA) I10LEDs (mA) I9LEDs (mA) I8LEDs (mA) I7LEDs (mA) I6LEDs (mA) 90 100 110 120 135 150 170 185 200 220 230 240 250 264 21.64 21.49 21.37 21.28 21.21 21.16 21.13 21.17 21.25 21.29 21.34 21.39 21.45 21.54 36.36 36.35 36.35 36.34 36.34 36.33 36.32 36.31 36.3 36.29 36.29 36.28 36.28 36.27 500 501 502 502 502 502 503 503 503 504 504 505 505 506 18.18 18.21 18.25 18.24 18.24 18.24 18.27 18.26 18.26 18.29 18.29 18.32 18.32 18.35 84.01 84.74 85.39 85.73 86.01 86.19 86.46 86.27 85.92 85.91 85.71 85.65 85.41 85.20 0.994 0.993 0.992 0.99 0.987 0.983 0.975 0.969 0.961 0.947 0.94 0.932 0.923 0.91 505 506 506 507 507 507 507 508 508 509 509 510 510 511 511 511 512 512 512 512 512 513 514 514 515 516 516 517 514 514 514 514 514 514 515 515 516 517 517 518 519 519 519 519 519 519 519 519 520 521 522 523 524 524 525 526 525 525 525 525 525 525 526 527 527 529 529 530 531 532 528 528 529 529 529 529 530 531 532 534 535 535 536 537 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 21.51 188.2 230/50 21.32 98.35 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 39 140.90 78.74 41.44 20.72 14.50 12.27 10.64 9.38 8.40 7.60 6.94 6.38 5.91 5.50 5.15 4.83 4.56 4.31 4.09 16.9 3.12 0.67 0.55 0.65 0.76 0.85 0.87 0.78 0.88 0.85 0.73 0.72 0.77 0.65 0.66 0.61 0.54 0.59 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 71.16 39.77 20.93 10.46 7.33 6.19 5.37 4.74 4.24 3.83 3.50 3.22 2.98 2.77 2.59 2.44 2.30 2.17 2.06 12.52 3.92 3.16 1.8 0.58 0.38 0.45 1.21 1.47 1.02 0.47 0.46 0.44 0.38 0.52 0.63 0.47 0.44 0.6 14.28 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-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 9 EV4026-J-00C– 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-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 10 EV4026-J-00C– EVB DESCRIPTION EVB TEST RESULTS Performance waveforms are tested on the evaluation board. 12 LEDs in series, ILED=500mA, VOUT=36V. 5% 100 1.00 4% 95 0.95 90 0.90 1% 0 85 0.85 80 0.80 -1% 75 0.75 70 0.70 -4% 65 0.65 -5% 90 110 130 150 170 190 210 230 250 270 60 90 110 130 150 170 190 210 230 250 270 0.60 90 110 130 150 170 190 210 230 250 270 3% 2% -2% -3% 120 110 EN55015O 100kHz 1 MHz 10 MHz 120 110 EN55015O 100kHz 1 MHz 10 MHz 120 110 100 100 100 90 90 90 80 80 80 70 70 70 60 60 50 50 EN55015A 60 40 40 30 30 30 20 20 20 10 10 10 0 0 120 110 30MHz 9kHz CDN_QP 50 EN55015A 40 9kHz 100 MHz 30MHz 0 30MHz 300MHz 100 MHz 100 90 80 70 60 CDN_QP 50 40 30 20 10 0 30MHz 300MHz EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 11 EV4026-J-00C– EVB DESCRIPTION EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. 12 LEDs in series, VIN=120VAC/60Hz, ILED=500mA, VOUT=36V. EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 12 EV4026-J-00C– EVB DESCRIPTION EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. 12 LEDs in series, VIN=230VAC/50Hz, ILED=500mA, VOUT=36V. EV4026-J-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 13 EV4026-J-00C– 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-00C Rev.1.1 www.MonolithicPower.com 12/30/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 14