LV5011MD-GU10-230VEVM03 [ For GU10 Application ] The Buck-Boost Converter for phase cut dimming With High Power Factor Application Note Ver1.03 LV5011MD-GU10-230VEVM03 Application Note 1. Introduction 2. Features 3. Performance Specifications 3.1. Application constitution 3.2. Electrical characteristics 4. Schematic 5. Evaluation Board 6. Test Setup 7. Test Procedure 7.1 Line/Load Regulation and Efficiency Measurement Procedure 7.2 Equipment Shutdown 7.3 Phase Angle Decode vs LED Current (at dimming) 8. Performance Data 8.1 Efficiency 8.2 Power factor 8.3 Line regulation 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 9. Board Layout 10. Bill of materials 11. Transformer specification 12. Detailed Descriptions for Application Circuit Setting 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-GU10-230VEVM03 is a 5W, 230VAC non-isolated dimmable LED driver for GU10 application. The LV5011MD-GU10-230VEVM03 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 = 25C) Table1. LV5011MD-GU10-230VEVM03 Electrical Performance Specifications Description Min Typ Max Units Input AC voltage 198 230 264 VAC Output voltage 48 V Output current 85 mA Efficiency 80 % Power Factor 0.74 Comment VAC=230V, 50Hz VAC=230V, 50Hz 4. Schematic LED+ AC R10 10k F1(Fuse) D1 S1ZB60 68/1W AC INPUT AC VR1 471 C1 0.033uF /275VAC R11 39k L1 C3 3.9mH 0.047uF /630V R1 68/1W C6 47uF/80V LED- R2 C4 680/3W 0.047uF /630V C2 0.22uF /630V D3 MURA160 R6 820k 4 (LED 5 series) (LED: OSW4Z3E1C1E) [OUTPUT=48V/85mA] 1 7 C5 4.7uF /50V D2 MRA4004 R9 100 5 T1 Core: EE10 (WE part No,750342001) R3 1.8M Transformer T1 specifications Inductance value 4-1 inductance L = 1.39mH Turns ratio (4-1) : (5-7) = 2.698 : 1 U1 LV5011MD 1 Drain 2 NC 3 VIN 4 ACS 5 C7 100pF R4 5.6k R5 0 LED OUT2 Source 10 NC 9 GND 8 CS REF_IN 7 6 R7 Open Figure1. LV5011MD-GU10-230VEVM03 Schematic R8 2.0 5. Evaluation Board LEDLED+ AC INPUT Figure2. LV5011MD-GU10-230VEVM03 Transformer Side 37.5mm 18mm Figure3. LV5011MD-GU10-230VEVM03 IC Side 6. Test Setup 6.1 Test Equipment Voltage Source: 230VAC AC source, NF EPO2000S Power Meter: HIOKI 3332 Volt Meter: ADVANTEST R6441D DIGITAL MULTIMETER AMP Meter: Agilent DIGITAL MULTIMETER 34401A Output Load: 5 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-GU10-230VEVM03 Line Dimmer Min At No Dimming, Connect this line LED- Max LED Figure4. LV5011MD-GU10-230VEVM03 Recommended Test Set Up 6.3 List of Test Points Table2. Test Points Functions TEST POINTS NAME DESCRIPTION Neutral 230VAC neutral connection Line 230VAC 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-GU10-230VEVM 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 230VAC. 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 198VAC to 264VAC 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-GU10-230VEVM 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 230VAC. 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 86 50Hz 60Hz Efficiency [ % ] 84 82 80 78 76 190 200 210 220 230 240 250 260 270 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 0.60 190 200 210 220 230 240 250 260 Input Voltage [ VAC ] Figure6. Power factor vs Input voltage 270 8.3 Line regulation LED Current (Output current) LED Current vs Input Voltage 120 50Hz 60Hz LED Current [ mA ] 110 100 90 80 70 60 190 200 210 220 230 240 250 260 270 Input Voltage [ VAC ] Figure7. LED current vs Input voltage Output Voltage Output Voltage vs Input Voltage 50.0 50Hz 60Hz Output Voltage [ V ] 49.5 49.0 48.5 48.0 47.5 47.0 190 200 210 220 230 240 250 260 270 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 [100mA/div] 5msec/div Figure9. Input waveform 8.5 Output voltage/current operation waveform (No dimming) CH1 Output voltage [20V/div] CH4 Output current (LED current) [50mA/div] 5msec/div Figure10. Output waveform 8.6 LED Current vs Phase angle [ Measurement condition: V AC=230V, 50Hz, Dimmer=MERTEN 572599 ] LED Current vs Phase angle 100 LED Current [mA] 90 80 70 60 50 40 30 20 10 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=230V, 50Hz, Dimmer=MERTEN 572599 ] Phase angle = 120 degree CH1 Input voltage =Dimmer output [200V/div] CH4 Input current [100mA/div] 5msec/div Figure12. Dimming operation waveform at phase angle=120degree Phase angle = 60 degree CH1 Input voltage =Dimmer output [200V/div] CH4 Input current [100mA/div] 5msec/div Figure13. Dimming operation waveform at phase angle=60degree 9. Board Layout Figure14. Transformer Side Layout Figure15. IC Side Layout Figure16. Board Size 10. Bill of materials No 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Designator Description Value Footprint Manufacturer Model Number C1 C2 C3 C4 C5 C6 C7 D1 D2 D3 L1 F1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 T1 U1 VR1 0.033uF/AC275V 0.22uF/630V 0.047uF/630V 0.047uF/630V 4.7uF/50V 47uF/80V 100pF/50V 600V/0.8A 400V/1A 600V/1A 3.9mH 68, 1W 68, 1W 680Ω, 3W 1.8Meg 5.6k 0 820k 2.0 Radial Radial Radial Radial 1206 8*11.5 0603 1Z(SMD) SMA SMA Radial Axial Axial Axial 0805 0603 0603 1206 0805 Okaya Murata Murata Murata Murata Rubycon Murata Shindengen Onsemi Onsemi WE Panasonic Panasonic Panasonic ROHM KOA KOA ROHM ROHM LE333 RDER72J224K5B1C13B RDER72J473K3K1C11B RDER72J473K3K1C11B GRM31CR71H475KA 80ZLJ47M GRM1882CH1H101JA01 S1ZB60 MRA4004T3G MURA160T3G 7447720392 ERQ1ABJ680 ERG1SJ680 ERG3SJ681 KTR10PZPZF1804 RK73H1JTTD562 RK73Z1JTTD000 KTR18EZPJ824 MCR10PZHZFL2R00 100 10k 39k 0603 0603 0603 EE10 SOIC10 Radial KOA KOA KOA WE midcom Onsemi Nippon Chemicon RK73H1JTTD101 RK73H1JTTD103 RK73H1JTTD393 750342001 rev.01 LV5011MD TND05V-471KB Metallized Polyester Film Capacitor Ceramic Capacitor, X7R Ceramic Capacitor, X7R Ceramic Capacitor, X7R Ceramic Capacitor, X7R Aluminum Electrolytic Capacitor Ceramic Capacitor, CH Bridge Diode Diode Power Rectifier, Ultra-Fast Inductor Metal Film Fuse Resistor Metal Film Resistor Metal Film Resistor Chip Resistor Chip Resistor Chip Resistor Chip Resistor Chip Resistor Open Chip Resistor Chip Resistor Chip Resistor Transformer LED Driver Varistor 470V 11.Transformer specification 12.Detailed Descriptions for Application Circuit Setting The LV5011MD-GU10-230VEVM03 is the non-isolated buck-boost converter with phase cut dimming. The explanation of each parts of the application circuit is described in figure17. How to set this application circuit is described below. Capacitor for smoothing output voltage LED+ R10 10k AC F1(Fuse) D1 S1ZB60 68/1W VR1 471 AC INPUT AC C1 0.033uF /275VAC R11 39k L1 3.9mH C3 0.047uF /630V R1 C4 0.047uF /630V 68/1W C6 47uF/80V LED LED- R2 680/3W Rectifier diode D3 MURA160 R6 820k C2 0.22uF /630V (LED 5 series) (LED: OSW4Z3E1C1E) 4 Filter for EMI and TRIAC dimming Start up resistor for HV regulator Filter for EMI and TRIAC dimming 1 [OUTPUT=48V/85mA] Transformer 7 Snubber circuit for TRIAC dimming D2 MRA4004 C5 4.7uF/50V Capacitor for VIN supply R3 1.8M Transformer T1 specifications Inductance value 4-1 inductance L = 1.39mH Turns ratio (4-1) : (5-7) = 2.698 : 1 R9 100 5 T1 Core: EE10 (WE part No,750342001) Auxiliary winding for VIN supply U1 LV5011MD 1 Resistors for REF_IN setting 2 3 4 5 C7 100pF R4 5.6k R5 0 Connect ACS pin to GND Drain Source NC NC VIN GND ACS OUT2 CS 10 9 8 7 Current sense resistor 6 REF_IN R7 Open Figure17. The description of each parts of LV5011MD-GU10-230VEVM03 R8 2.0 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 Figure18. REF_IN pin setting R4 R11 REF_IN peak = R3+R4 × VAC peak + R10+R11 × VOUT = 0.9 ~ 1.3 [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)=230V, VOUT =48V R3=1800kΩ, R4=5.6kΩ, R10=10kΩ, R11=39kΩ 5.6 39 REF_IN peak = 1800+5.6 × 230× 2 + 10+39 × 48 = 1.13 [V] 5.6 39 REF_IN min = 1800+5.6 × 10+39 × 48 = 0.12 [V] 12.2 Transformer design At first calculate the inductance “L1” which is used at Internal MOSFET switching. The inductance “L1” is calculated 2 L1 = 2 (VAC peak) × D1 × 0.1388 POUT × f Transformer current I1 peak Rectifier diode current Internal MOSFET current where, L1 : Inductance used at internal MOSFET switching VAC peak : Input peak voltage f : Switching frequency = 70k [Hz] POUT : Output power POUT = VOUT × IOUT VOUT : Output voltage (LED voltage) Time IOUT : Output current (LED current) D1 : Duty of Internal MOSFET “ON” T1 D1 = T T2 T1 T Figure19. Transformer current T1 : Time of internal MOSFET “ON” LED+ T : Switching period = 1/70k [sec] Vf “D2 ” is calculated L1 [Turns: N1] T2 I1 peak × L1 D2 = T = T × (V OUT + Vf ) where, D2 : Duty of the rectifier diode ON T2 : Time of the rectifier diode ON Vf : Forward voltage of the rectifier diode I1 peak : Peak current of L1 (*Refer to section “12.3”) Confirm “I1 peak” and choose the rectifier diode to permit it. LED- Rectified AC voltage Drain VIN [Turns: Nd] Transformer Figure20. Transformer Inductance and Turns To operate in the current discontinuous mode, decide “D1”, “D2” and “L1” by the above expressions. And also actually check that the operation with the designed transformer is the current discontinuous mode. The auxiliary winding turns Nd is calculated Nd VIN = N1 VOUT where, Nd : Turns of auxiliary winding VIN : VIN pin voltage Design the most suitable transformer depending on the necessary application specifications. 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 × 0.168 POUT R7 × R8 R7 + R8 = Figure21 is the operation outline diagram. Internal MOSFET current (= L1 current) Rectified AC voltage L1 REF_IN 0.9V~1.3V LV5011MD inside REF_IN CLK - VREF Q RESET Internal MOSFET current (= L1 current) Reference VREF (0.605Vtyp) Internal MOSFET + (0.605Vtyp) T ON Internal MOSFET Gate OFF CS Ton R7 R8 Reference =REF_IN Toff Reference =0.605V Reference =REF_IN Figure21. Operation outline diagram (No dimming) 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 230VAC, the recommended value of R6 is 820kΩ. D1 T1 R6 LV5011MD VIN D2 C5 Figure22. 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