LV5012MD-A19-120VEVM04 [ For A19/E27 LED Bulb Application ] The single stage flyback converter for phase cut dimming with High Power Factor Application Note Ver1.04 LV5012MD-A19-120VEVM04 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 Switching operation waveform 8.7 LED current vs Phase angle 8.8 Dimming operation waveform 8.9 EMI data 9. Board Layout 10. Bill of materials 11. Transformer specification 12. Detailed Descriptions for Application Circuit Setting 12.1 Transformer design 12.2 REF_IN pin and ALC_C pin setting 12.3 CS pin setting 12.4 ACS pin and DML pin setting 12.5 HV pin setting 12.6 Protection function 1. Introduction The LV5012MD-A19-120VEVM04 is a 14W, 120VAC isolated dimmable LED driver for A19 and E27 applications. The LV5012MD-A19-120VEVM04 is a primary-side power regulated PFC controller used for commercial and residential phase-cut dimmer compatible LED lamp drivers. 2. Features • Primary Side Flyback Control With Integrated PFC • Compatible With Leading and Trailing Edge Dimmer • Constant Current & Improved THD • Short Protection - [latch off] • Over Voltage Protection -[auto recovery] • 2 Stage Thermal Protection -[auto recovery] 3. Performance Specifications 3.1. Application constitution Isolation Flyback with Phase Cut Dimming 3.2. Electrical characteristics (Operating Temperature = 25C) Table1. LV5012MD-A19-120VEVM04 Electrical Performance Specifications Description Min Typ Max Units Input AC voltage 108 120 132 VAC Output voltage 20 V Output current 550 mA Efficiency 83 % Power Factor 0.96 Comment 2parallel of 6LEDs series VAC=120V, 60Hz VAC=120V, 60Hz 4. Schematic AC1 R1 F1 10/1W 15/2W C1 AC INPUT AC2 R3 1k/1W 0.033uF /AC275V VR1 R2 L1 15/2W 0 D1 S1ZB60 L2 R4 0 C4 0.1uF /630V 1.0mH C5 2.2nF /630V C3 0.33uF/450V C2 0.1uF /630V D4 MURA140 F R5 R7 390k 270k R9 1.0k R10 12k C12 4.7uF /50V U1 MMSD103 1 HV OUT DML GND 2 Transformer T1 specifications Inductance value 1-3 inductance Lp = 0.7mH S-F inductance Ls = 32uH Turns ratio (4-6) : (S-F) = 1 : 1.14 3 4 NC VIN GND CS ENB REF_IN ACS TRC 5 4 3.3k R8 10k R11 0 7 [Output=20V,550mA] 22 Q1 NDD03N50 R12 12 11 LED- R16 R17 100k 4.7Meg C11 2.2nF/AC250V 9 REF_OUT ALC_C R20 27k S 10 6 R6 C10 1000uF /35V 6 0 13 LED+ 3 R15 14 D5 MBRS4201 2 LV5012MD 150pF T1 1 D3 C7 (6 LEDs in series)×2parallel [LED: NICHIA NS6W083AT] R14 100k /1W 8 C8 C9 0.1uF 1uF Figure1. LV5012MD-A19-120VEVM04 Schematic R18 1.2 R19 0.91 5. Evaluation Board LEDAC INPUT LED+ Figure2. LV5012MD-A19-120VEVM04 Transformer Side 64mm 24mm Figure3. LV5012MD-A19-120VEVM04 IC Side 6. Test Setup 6.1 Test Equipment Voltage Source: 120VAC AC source, NF EPO2000S Power Meter: HIOKI 3332 Volt Meter: ADVANTEST R6441D DIGITAL MULTIMETER AMP Meter: Agilent DIGITAL MULTIMETER 34401A Output Load: 2 Parallel of 6 LEDs series (LED: NICHIA NS6W083AT) Oscilloscope: LeCroy WaveRunner 6050A Operating Temperature: 25C 6.2 Recommended Test Setup Volt Meter + Power Meter Neutral AC Source AC INPUT AMP Meter LED+ LV5012MD-A19-120VEVM04 Line Dimmer Min Max At No Dimming, Connect this line LED2 Parallel of 6 LEDs series Figure4. LV5012MD-A19-120VEVM04 Recommended Test Set Up 6.3 List of Test Points Table2. Test Points Functions TEST POINTS NAME DESCRIPTION Neutral 120VAC neutral connection Line 120VAC line voltage LED+ LED anode connection LED- LED cathode connection 7. Test Procedure 7.1 Line/Load Regulation and Efficiency Measurement Procedure 1. Connect LV5012MD-A19-120VEVM 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 120VAC. 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 108VAC to 132VAC 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 LV5012MD-A19-120VEVM 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 120VAC. 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 87 50Hz 86 60Hz Efficiency [ % ] 85 84 83 82 81 80 79 78 77 100 110 120 130 140 Input Voltage [ VAC ] Figure5. Efficiency vs Input voltage 8.2 Power factor Power Factor vs Input Voltage 1.00 50Hz 60Hz Power Factor 0.98 0.96 0.94 0.92 0.90 0.88 0.86 100 110 120 130 Input Voltage [ VAC ] Figure6. Power factor vs Input voltage 140 8.3 Line regulation LED Current (Output current) LED Current vs Input Voltage 600 50Hz 590 60Hz LED Current [ mA ] 580 570 560 550 540 530 520 510 500 100 110 120 130 140 Input Voltage [ VAC ] Fgure7. LED current vs Input voltage Output Voltage Output Voltage vs Input Voltage 20.5 50Hz 20.4 60Hz Output Voltage [ V ] 20.3 20.2 20.1 20.0 19.9 19.8 19.7 19.6 19.5 100 110 120 130 Input Voltage [ VAC ] Figure8. Output voltage vs Input voltage 140 8.4 Input voltage/current operation waveform (No dimming) CH1 Input voltage (VAC) [100V/div] CH4 Input current [200mA/div] 5msec/div Figure9. Input waveform 8.5 Output voltage/current operation waveform (No dimming) CH1 Output voltage [5V/div] CH4 Output current (LED current) [200mA/div] 5msec/div Figure10. Output waveform 8.6 Switching operation waveform CH1 Q1 Drain voltage [100V/div] CH4 Q1 current [500mA/div] 10usec/div Figure11. Switching operation waveform 8.7 LED Current vs Phase angle [ Measurement condition: V AC=120V, 60Hz, Dimmer= LEVITON IPI06 ] LED Current vs Phase angle 600 LED Current [mA] 500 400 300 200 100 0 0 20 40 60 80 100 120 140 160 180 phase angle [ deg ] Figure12. LED current vs Phase angle 8.8 Dimming operation waveform [ Measurement condition: V AC=120V, 60Hz, Dimmer= LEVITON IPI06 ] Phase angle = 120 degree CH1 Input voltage =Dimmer output [100V/div] CH4 Input current [200mA/div] 5msec/div Figure13. Dimming operation waveform at phase angle=120degree Phase angle = 60 degree CH1 Input voltage =Dimmer output [100V/div] CH4 Input current [200mA/div] 5msec/div Figure14. Dimming operation waveform at phase angle=60degree 8.9 EMI data Conducted Emission QP Measurement [ Measurement condition: VAC=120V,60Hz ] Phase1 Phase2 Figure15. Conducted Emission, QP Measurement 9. Board Layout Figure16. Transformer Side Layout Figure17. IC Side Layout Figure18. Board Size 10.Bill of materials No Designator Description Value Footprint Manufacturer Manufacturer Part Number 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 C1 C2 C3 C4 C5 C7 C8 C9 C10 C11 C12 D1 D3 D4 D5 F1 L1 L2 Q1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R14 R15 R16 R17 R18 R19 R20 T1 U1 VR1 Metallized Polyester Film Capacitor Capacitor,Ceramic,X7R Capacitor,Ceramic,X7T Capacitor,Ceramic,X7R Capacitor,Ceramic,X7R Capacitor,Ceramic,CH Capacitor,Ceramic,X7R Capacitor,Ceramic,X7R Aluminum Electrolytic Capacitor Capacitor,Ceramic,E Capacitor,Ceramic,X7R Diode,Bridge Diode Diode,Ultrafast Diode,Schottky Metal Film Fuse Resistor Jumper Power Inductor N-Channel Power MOSFET Metal Film Resistor Metal Film Resistor Metal Film Resistor Jumper Chip Resistor Chip Resistor Chip Resistor Chip Resistor Anti-surge Chip Resistor Anti-surge Chip Resistor Jumper Chip Resistor Metal Film Resistor Jumper Chip Resistor Chip Resistor Low Ohmic Chip Resistor Low Ohmic Chip Resistor Anti-surge Chip Resistor Transformer LED Driver Varistor 0.033uF/275VAC 0.1uF/630V 0.33uF/450V 0.1uF/630V 2.2nF/630V 150pF/50V 0.1uF/50V 1uF/25V 1000uF/35V 2.2nF/250VAC 4.7uF/50V 0.8A,600V 0.2A,250V 1A,400V 4A,200V 10,1W 0 1.0mH 500V,2.6A 15,2W 15,2W 1k,1W 0 390k 3.3k,1% 270k 10k,1% 1.0k 12k 0 4.7Meg 100k,1W 0 22 100k 1.2,1% 0.91,1% 27k Radial Radial Radial Radial 1206 0603 0603 0603 Radial Radial 1206 1Z(SMD) SOD-123 SMA SMC Axial Radial DPAK Axial Axial Axial 1206 0603 1206 0603 1206 1206 0603 0603 Axial 0603 0603 0603 0805 0805 1206 RM6 MFP14S Radial OKAYA MURATA MURATA MURATA MURATA MURATA MURATA MURATA Rubycon MURATA MURATA SHINDENGEN ON Semiconductor ON Semiconductor ON Semiconductor Panasonic Sumida ON Semiconductor Panasonic Panasonic Panasonic Rohm KOA Rohm KOA Rohm Rohm KOA Panasonic Panasonic KOA KOA KOA Rohm Rohm Rohm WE-Midcom ON Semiconductor Nippon Chemi-con LE333 RDER72J104K8K1C11B RDED72W334K5B1C13B RDER72J104K8K1C11B GRM31BR72J222KW01L GRM1882CH1H151JA01 GRM188R71H104KA93D GRM188R71E105KA12D 35ZLH1000 DE1E3KX222MA4BL01 GRM31CR71H475KA12L S1ZB60 MMSD103T1G MURA140T3G MBRS4201T3G ERQ1ABJ100 RCH895NP-102K NDD03N50Z ERG2SJ150 ERG2SJ150 ERG1SJ102 KTR18EZPJ394 RK73H1JTTD332 KTR18EZPJ274 RK73H1JTTD103 ESR18EZPJ102 ESR18EZPJ123 RK73Z1JTTD000 ERJ3GEYJ475V ERG1SJ104 RK73Z1JTTD000 RK73B1JTTD220 RK73B1JTTD104 MCR10EZHFL1R20 MCR10EZHFLR910 ESR18EZPJ273 750341533 Rev.04 LV5012MD TND05V-271KB AC175V 11.Transformer specification 12.Detailed Descriptions for Application Circuit Setting The LV5012MD-A19-120VEVM04 is the isolated flyback converter with phase cut dimming. The explanation of each parts of the application circuit is described in figure19. How to set this application circuit is described below. AC1 R1 F1 10/1W Snubber circuit for TRIAC dimming 15/2W R3 1k/1W AC INPUT VR1 C1 0.033uF /AC275V AC2 R2 15/2W C4 0.1uF /630V Filter for EMI and TRIAC dimming Snubber circuit D1 S1ZB60 R4 L2 0 1.0mH C2 0.1uF /630V R14 100k /1W C5 C3 0.33uF/450V 2.2nF /630V D4 MURA140 L1 Transformer Secondary side rectifier diode T1 F 1 0 D3 Filter for EMI and TRIAC dimming Resistors for ALC function R5 390k R9 1.0k R7 Capacitor for VIN supply R10 12k U1 270k C12 4.7uF /50V MMSD103 HV OUT DML GND 2 Resistor for bleeder current Resistors for TRIAC ON/OFF detection setting and bleeder current setting 3 4 NC VIN GND CS ENB REF_IN ACS TRC 5 Transformer T1 specifications Inductance value 1-3 inductance Lp = 0.7mH S-F inductance Ls = 32uH Turns ratio (4-6) : (S-F) = 1 : 1.14 C7 150pF R6 3.3k R8 10k R11 7 R20 27k C10 6 1000uF /35V 0 4 S LED- R16 14 R17 100k 13 22 Q1 NDD03N50 R12 12 Capacitor for smoothing output voltage Power MOSFET 4.7Meg 11 C11 10 6 LED+ 3 R15 LV5012MD 1 D5 MBRS4201 2 Auxiliary winding for VIN supply Start up resistor for HV regulator (6 LEDs in series)×2parallel [LED: NICHIA NS6W083AT] 2.2nF/AC250V 9 REF_OUT ALC_C 8 C8 C9 0.1uF 1uF 0 Capacitor for ALC function R18 1.2 R19 0.91 Current sense resistor Figure19. The description of each parts of LV5012MD-A19-120VEVM04 Capacitor for noise reduction 12.1 Transformer design At first calculate about primary inductance and secondary inductance. The primary inductance Lp is calculated (VAC peak) 2 × Dp2 × η × 0.565 Lp = 2 × POUT × f where, Lp : Primary side inductance VAC peak : Input peak voltage η : Conversion efficiency of transformer f : Switching frequency = 70k [Hz] POUT : Output power of secondary side Transformer current Is peak Primary current Secondary current Ip peak POUT = VOUT × IOUT VOUT : Output voltage (LED voltage) IOUT : Output current (LED current) Dp : Duty of primary side current Tp Dp = T Time Tp Ts T Figure20. Transformer current Tp : Time of primary side current T : Switching period = 1/70k [sec] The secondary inductance Ls is calculated (VOUT + Vf ) 2 × Ds 2 Ls = L × (I peak) 2 × f 2 p p Transformer LED+ Rectified AC voltage where, Ls : Secondary side inductance Vf : Forward voltage of the rectifier diode Lp [Turns: Np] Ip peak : Peak current of Primary side inductance “Lp” (*Refer to section “12.3”) Ds : Duty of secondary side current Vf Ls [Turns: Ns] [Turns: Nd] LED- Ts Ds = T Ts : Time of secondary side current Figure21. Transformer Turns Next calculate about Turns Raito by primary inductance and secondary inductance. Np Ns = Lp Ls where, Np : Turns of primary side Ns : Turns of secondary side Design the most suitable transformer with the winding turns ratio and the inductance value. Confirm that the operation with the designed transformer is a current discontinuous mode. The auxiliary winding turns Nd is calculated Nd VIN = Ns VOUT where, Nd : Turns of auxiliary winding VIN : VIN pin voltage 12.2 REF_IN pin and ALC_C pin setting R5, R6 setting Please set R5, R6 so that the voltage peak of the REF_IN pin is around 1.1V to 1.9V. e.g. VAC=120V → R5=390kΩ, R6=3.3kΩ REF_IN peak = (120V×√2) × 3.3k / (390k+3.3k) = 1.42V C8 setting Please connect capacitor of about 0.1uF to an ALC_C pin. By the above setting, ALC function of LV5012MD becomes effective. Thereby the application of LV5012MD can achieve good line regulation and total harmonic distortion. 12.3 CS pin setting R18, R19 setting The output power of second side is set by the current sense resistor (R18, R19) connected to CS pin. The current sense resistor is calculated, 0.141 × Lp × f × η 2 × POUT R18 × R19 R18 + R19 = Figure22 is the operation outline diagram. Rectified AC voltage LV5012MD inside ALC_out Auto Level Control VREF (0.45Vtyp) + CLK Q RESET Lp Q1 current (Primary side current) ALC_out OUT VREF (0.45Vtyp) Q1 Q1 current 0.5Vtyp Reference CS T R18 R19 ON OUT (Q1 Gate) OFF Ton Toff Reference=ALC_out Reference =0.45V Figure22. Operation outline diagram (No dimming) The peak current of Lp “Ip peak” is the following expression. R18 + R19 Ip peak = R18 × R19 × 0.45 ( In the case of ALC_out > VREF(0.45V) ) Reference=ALC_out 12.4 ACS pin and DML pin setting LV5012MD contains the function for TRIAC dimming. This function is operated by setting ACS pin and DML pin. Figure23 is the outline diagram of TRIAC dimming operation. Please set the TRIAC ON/OFF threshold and the Bleeder operation threshold in tune with the characteristic of TRIAC dimmer. The TRIAC ON/OFF threshold and the Bleeder operation threshold are calculated as follow. The TRIAC ON threshold of the rectified AC is determined below. R7 + R8 Vac_triac on = × 1.7 R8 The TRIAC OFF threshold of the rectified AC is determined below. R7 + R8 Vac_triac off = × 1.3 R8 The Bleeder operation threshold of the rectified AC is determined below. R7 + R8 × 0.85 R8 Vac_bleeder = Please set R7, R8 on the basis of these expressions according to TRIAC dimmer. In addition, please set R9 between the rectified AC voltage and DML pin to satisfy the following expression. R7 + R8 × 0.85 - ( R9 × 0.02 ) < 50 [V] R8 Rectified TRIAC OUT Rectified AC voltage ACS Rectified AC voltage Bleeder current R9 0.85V + ACS + Auto Level Control 0.85V T Built-in MOSFET for Bleeder current Bleeder MOS gate Lp ALC_out CLK - 1.7V 1.3V LV5012MD inside - R7 Q RESET 0.1V - 1.3V R8 1.7V DML VREF (0.45Vtyp) + TRIAC ON OUT TRIAC OFF ALC_out Q1 Q1 current VREF (0.45Vtyp) CS R18 Q1 current (Primary side current) Reference R19 0.1V T TRIAC OFF TRIAC ON TRIAC OFF Bleeder MOS gate Bleeder MOS ON Bleeder MOS OFF Figure23. Outline diagram of TRIAC dimming operation Bleeder MOS ON 12.5 HV pin setting R10 setting LV5012MD has a high voltage regulator built-in for self-supplying from the rectified AC voltage. It outputs 12V, and thereby the circuit in the IC starts. Please connect R10=12kΩ between HV pin and the rectified AC voltage to operate HV regulator normally. 12.6 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 80uA 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 external 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 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 stopping operation is kept until the voltage of VIN is lower than VINOVP(27Vtyp). If the voltage of VIN pin is lower than VINOVP(27Vtyp), the switching operation is restated. Pease see OVP waveform chart. OVP VIN voltage OVP release 27Vtyp time Output stage on off on 4. OTP(Over thermal protection) LV5012MD has the gradually thermal protection system. If the junction temperature exceeds 140 degrees Celsius, 1st stage protection mode is started. At 1st stage protection mode, the internal reference level compared with CS pin voltage is set to 0.1V. And the LED current is restricted to low values (approximately 5%). If the junction temperature exceeds 155 degrees Celsius, the switching operation and startup circuit are stopped. Please see OTP waveform chart. 155℃ 143℃ 140℃ IC Junction Temperature 128℃ Time 100% LED Current Normal Condition Normal Condition 1st Stage Thermal Protection Normal Condition Thermal Shut Down Time Approximately 5%