LV5012MD-A19-220VEVM03 [ For A19/E27 LED Bulb Application ] The single stage flyback converter for phase cut dimming with High Power Factor Application Note Ver1.03 LV5012MD-A19-220VEVM03 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-A19-220VEVM03 is a 14W, 220VAC isolated dimmable LED driver for A19 and E27 applications. The LV5012MD-A19-220VEVM03 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-A19-220VEVM03 Electrical Performance Specifications Description Min Typ Max Units Input AC voltage 198 220 264 VAC Output voltage 20 V Output current 550 mA Efficiency 82 % Power Factor 0.95 Comment 2parallel of 6LEDs series VAC=220V, 50Hz VAC=220V, 50Hz 4. Schematic AC1 F1 33/1W AC INPUT R1 47/2W VR1 C1 0.033uF /AC275V R21 Open AC2 R2 R3 56/2W 0 D1 S1ZB60 R4 L2 10/1W 4.7mH C3 0.1uF/630V C2 D2 MRA4005 R13 820/2W C5 4.7nF /630V 47nF/630V L1 4.7mH D3 R5 R7 680k 470k R9 1.2k R10 12k U1 LV5012MD 1 2 Transformer T1 specifications Inductance value 1-3 inductance Lp = 2.0mH S-F inductance Ls = 42uH Turns ratio (4-6) : (S-F) = 1 : 1.18 3 4 5 6 C7 150pF R6 R8 2.7k 12k R11 0 7 C12 4.7uF /50V MMSD103 OUT 14 DML GND 13 VIN 12 GND CS ENB REF_IN ACS TRC REF_OUT ALC_C T1 F 1 3 R15 C10 1000uF /35V 6 0 11 22 27k Q1 NDD03N60 R12 C11 2.2nF/AC250V 10 9 R18 8 0.1uF R20 LED- 4.7Meg C8 LED+ S R16 R17 100k D5 MBRS4201 2 4 HV NC R14 100k /1W D4 MURA160 C4 0.1Fu/630V (6 LEDs in series)×2parallel [LED: NICHIA NS6W083AT] C9 1uF Figure1. LV5012MD-A19-220VEVM03 Schematic 0.91 R19 Open 5. Evaluation Board LEDAC INPUT LED+ Figure2. LV5012MD-A19-220VEVM03 Transformer Side 64mm 24mm Figure3. LV5012MD-A19-220VEVM03 IC Side 6. Test Setup 6.1 Test Equipment Voltage Source: 220VAC 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: 25℃ 6.2 Recommended Test Setup Volt Meter + Power Meter AMP Meter Neutral AC Source AC INPUT LED + LV5012MD-A19-220VEVM03 Line Dimmer Min At No Dimming, Connect this line LED- Max 2 Parallel of 6 LEDs series Figure4. LV5012MD-A19-220VEVM03 Recommended Test Set Up 6.3 List of Test Points Table2. Test Points Functions TEST POINTS NAME DESCRIPTION Neutral 220VAC neutral connection Line 220VAC 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-A19-220VEVM 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 220VAC. 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 LV5012MD-A19-220VEVM 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 220VAC. 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 77 190 200 210 220 230 240 250 260 270 Input Voltage [ VAC ] Figure5. Efficiency vs Input voltage 8.2 Power factor Power Factor vs Input Voltage 1.00 50Hz 60Hz Power Factor 0.98 0.96 0.94 0.92 0.90 0.88 0.86 190 200 210 220 230 240 250 Input Voltage [ VAC ] Figure6. Power factor vs Input voltage 260 270 8.3 Line regulation LED Current (Output current) LED Current vs Input Voltage 600 50Hz 590 60Hz LED Current [ mA ] 580 570 560 550 540 530 520 510 500 190 200 210 220 230 240 250 260 270 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 19.5 190 200 210 220 230 240 250 260 Input Voltage [ VAC ] Figure8. Output voltage vs Input voltage 270 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 [5V/div] CH4 Output current (LED current) [200mA/div] 5msec/div Figure10. Output waveform 8.6 Switching operation waveform CH1 Q1 Drain voltage [200V/div] CH4 Q1 current [500mA/div] 10usec/div Figure11. Switching operation waveform 8.7 LED Current vs Phase angle [ Measurement condition: V AC=230V, 50Hz, Dimmer= MERTEN 572599 ] 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=230V, 50Hz, Dimmer= MERTEN 572599 ] Phase angle = 120 degree CH1 Input voltage =Dimmer output [200V/div] CH4 Input current [100mA/div] 5msec/div Figure13. 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 Figure14. Dimming operation waveform at phase angle=60degree 8.9 EMI data Conducted Emission QP Measurement [ Measurement condition: V AC=230V, 50Hz ] 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 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 C1 C2 C3 C4 C5 C7 C8 C9 C10 C11 C12 D1 D2 D3 D4 D5 F1 L1 L2 Q1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 T1 U1 VR1 Metallized Polyester Film Capacitor Capacitor,Ceramic,X7R Capacitor,Ceramic,X7R 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,STD Recovery Diode Diode,Ultrafast Diode,Schottky Metal Film Fuse Resistor Power Inductor Power Inductor N-Channel Power MOSFET Metal Film Resistor Metal Film Resistor Jumper Metal Film Resistor Chip Resistor Chip Resistor Chip Resistor Chip Resistor Anti-surge Chip Resistor Anti-surge Chip Resistor Jumper Chip Resistor Metal Film Resistor Metal Film Resistor Jumper Chip Resistor Chip Resistor Low Ohmic Chip Resistor Open Anti-surge Chip Resistor Open Transformer LED Driver Varistor 0.033uF/275VAC 47nF/630V 0.1uF/630V 0.1uF/630V 4.7nF/630V 150pF/50V 0.1uF/50V 1uF/25V 1000uF/35V 2.2nF/250VAC 4.7uF/50V 0.8A,600V 1A,600V 0.2A,250V 1A,600V 4A,200V 33,1W 4.7mH 4.7mH 600V,2.6A 47,2W 56,2W 0 10,1W 680k 2.7k,1% 470k 12k,1% 1.2k 12k 0 4.7Meg 820,2W 100k,1W 0 22 100k 0.91,1% 27k - Radial Radial Radial Radial 1206 0603 0603 0603 Radial Radial 1206 1Z(SMD) SMA SOD-123 SMA SMC Axial Radial Radial DPAK Axial Axial Axial 1206 0603 1206 0603 1206 1206 0603 0603 Axial Axial 0603 0603 0603 0805 1206 RM6 MFP14S Radial OKAYA MURATA MURATA MURATA MURATA MURATA MURATA MURATA Rubycon MURATA MURATA SHINDENGEN ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor Panasonic Sumida Sumida ON Semiconductor Panasonic Panasonic Panasonic Rohm KOA Rohm KOA Rohm Rohm KOA Panasonic Panasonic Panasonic KOA KOA KOA Rohm Rohm WE-Midcom ON Semiconductor Nippon Chemi-con LE333 RDER72J473K3K1C11B RDER72J104K8K1C11B RDER72J104K8K1C11B GRM31BR72J472KW01L GRM1882CH1H151JA01 GRM188R71H104KA93D GRM188R71E105KA12D 35ZLH1000 DE1E3KX222MA4BL01 GRM31CR71H475KA12L S1ZB60 MRA4005T3G MMSD103T1G MURA160T3G MBRS4201T3G ERQ1ABJ330 RCH895NP-472K RCH895NP-472K NDD03N60Z ERG2SJ470 ERG2SJ560 ERG1SJ100 KTR18EZPJ684 RK73H1JTTD272 KTR18EZPJ474 RK73H1JTTD123 ESR18EZPJ122 ESR18EZPJ123 RK73Z1JTTD000 ERJ3GEYJ475V ERG2SJ821 ERG1SJ104 RK73Z1JTTD000 RK73B1JTTD220 RK73B1JTTD104 MCR10EZHFLR910 ESR18EZPJ273 750341585 Rev.6A LV5012MD TND05V-471KB00AAA0 470V 11.Transformer specification 12.Detailed Descriptions for Application Circuit Setting The LV5012MD-A19-220VEVM03 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 F1 33/1W R1 Filter for EMI and TRIAC dimming 47/2W Snubber circuit for TRIAC dimming Snubber circuit AC INPUT VR1 C1 0.033uF /AC275V R21 Open AC2 R2 56/2W D1 S1ZB60 L2 R4 4.7mH 10/1W C2 47nF/630V R13 C3 0.1uF/630V 820/2W Start up resistor for HV regulator L1 4.7mH Filter for EMI and TRIAC dimming Resistors for ALC function R5 R7 680k 470k R9 1.2k 12k U1 LV5012MD 1 2 Resistor for bleeder current Resistors for TRIAC ON/OFF detection setting and bleeder current setting 3 4 5 6 Transformer T1 specifications Inductance value 1-3 inductance Lp = 2.0mH S-F inductance Ls = 42uH Turns ratio (4-6) : (S-F) = 1 : 1.18 C7 150pF R6 R8 2.7k 12k R11 7 D3 C12 4.7uF /50V HV OUT DML GND NC VIN GND CS ENB REF_IN ACS TRC REF_OUT D4 MURA160 ALC_C MMSD103 Secondary side rectifier diode T1 F 3 C10 1000uF /35V 6 0 4 R17 100k 13 R12 12 11 LED+ R20 27k S LED- R16 14 D5 MBRS4201 2 R15 (6 LEDs in series)×2parallel [LED: NICHIA NS6W083AT] Transformer 1 Auxiliary winding for VIN supply Capacitor for VIN supply R10 R14 100k /1W C5 4.7nF /630V C4 0.1uF/630V R3 0 D2 MRA4005 22 Q1 NDD03N60 Power MOSFET Capacitor for smoothing output voltage 4.7Meg C11 2.2nF/AC250V 10 9 R18 8 0 C8 C9 0.1uF 1uF Capacitor for ALC function Figure19. The description of each parts of LV5012MD-A19-220VEVM03 0.91 R19 Open Current sense resistor 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 where, Ls : Secondary side inductance Vf : Forward voltage of the rectifier diode Ip peak : Peak current of Primary side inductance “Lp” LED+ Transformer Rectified AC voltage Lp [Turns: Np] Vf Ls [Turns: Ns] [Turns: Nd] (*Refer to section “12.3”) Ds : Duty of secondary side current 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=220V → R5=680kΩ, R6=2.7kΩ REF_IN peak = (220V×√2) ×2.7k / (680k+2.7k) = 1.23V 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 Q1 current (Primary side current) ALC_out Lp VREF (0.45Vtyp) OUT 0.5Vtyp Reference Q1 Q1 current 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 LV5012MD inside - R7 0.85V + ACS + Auto Level Control 1.7V T Lp ALC_out CLK Q RESET 0.1V - 1.3V VREF (0.45Vtyp) + 1.3V 0.85V Built-in MOSFET for Bleeder current Bleeder MOS gate - R8 1.7V DML TRIAC OFF TRIAC ON OUT ALC_out Q1 VREF (0.45Vtyp) Q1 current 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. Please 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%