EV4027-J-00A Universal Input, 7W Primary-side-control with Active PFC Offline WLED Driver Evaluation Board For A19 Bulb DESCRIPTION FEATURES The EV4027-J-00A Evaluation Board is designed to demonstrate the capabilities of MP4027. The MP4027 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 EV4027-J-00A is typically designed for driving an isolated 7W A19 LED bulb with 20VTYP, 350mA LED load at universal input (90V~265VAC, 50/60Hz). The EV4027-J-00A 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, NTC, etc. ELECTRICAL SPECIFICATION Parameter Input Voltage Output Voltage LED Current Output Power Efficiency (full load) PF Symbol Value Units VIN VOUT ILED POUT 90 ~ 265 20 350 7 VAC V mA W η 84~87 % Small IC package: SOT23-8 Real current control without secondaryfeedback circuit Good line/load regulation High power factor>0.9 over universal input voltage Boundary conduction mode improves efficiency NTC function PWM dimming available Input UVLO Primary-side over current protection Over-voltage protection Short-circuit protection Over-temperature protection Fit inside A19 bulb enclosure APPLICATIONS 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. >0.9 EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 1 EV4027-J-00A– EVB DESCRIPTION EV4027-J-00A EVALUATION BOARD (L x W x H) 66mm x 22.6mm x 23mm Board Number MPS IC Number EV4027-J-00A MP4027GJ EVALUATION BOARD SCHEMATIC Figure 1 - Schematic EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 2 EV4027-J-00A– EVB DESCRIPTION PCB LAYOUT (DOUBLE-SIDED) Figure 2 - Top Layer Figure 3 - Bottom Layer EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 3 EV4027-J-00A– EVB DESCRIPTION CIRCUIT DESCRIPTION The EV4027-J-00A is configured in a singlestage Flyback topology, it uses primary-sidecontrol which can mostly simplify the schematic and et a cost effective BOM. It can also achieve high power factor and accurate LED current. F1, RV1, CX1, L1 ， L2, L3, C2 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, R2, R3 and C2 associated with CY1 form the EMI filter which can meet the requirement for universal input. The diode rectifier BD1 rectifies the input line voltage. Small bulk CBB capacitor C2 is used for a low impedance path for the primary switching current, to maintain high power factor, the capacitance of C4 should be selected with low value. R5, R6, C4 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. R4, C3, D2, R15 are used to supply the power for MP4027. A 4.7μF ceramic capacitor C3 is selected to maintain the supply voltage. At startup, C3 is first charged up by the starter resistor R4 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 R15, D2. R9, R10, D4, C1 are used to detect the auxiliary winding to get the transformer magnetizing current zero crossing signal for realizing the boundary conduction operation, and also monitor the output OVP condition. The OVP voltage is set by the divider ratio of R9, R10. D4 is used to block the negative plateau voltage of auxiliary winding when MOSFET is turn on. C1 is used to decouple the high frequency noise influence on CS/ZCD pin. R11, R12 are primary sensing resistors for primary side current control. The value of R11, R12 set the output LED current. R7 is used to form a feedforward from input line voltage to optimize the line regulation. C6, R14, D3 are used to damp the leakage inductance energy so the drain voltage can be suppressed at a safe level. NTC is a 220kΩ thermistor to set the thermal protection point, C7 is used to absorb the high frequency noise in NTC pin. Diode D1 rectifies the secondary winding voltage and the capacitor C8, C9 are the output filter. The resistor R13 is placed as pre-load to limit the output voltage rise too high in open load condition. EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 4 EV4027-J-00A– EVB DESCRIPTION EV4027-J-00A BILL OF MATERIALS Qty Ref Value Description 1 BD1 MB6S BRIDGE, 600V, 0.5A 1 1 1 1 1 C1 C2 C3 C4 C5 10pF/50V 100nF/400V 4.7μF/50V 2.2nF/50V 1μF/10V 1 C6 22nF/630V 1 C7 2.2nF/50V 2 C8,C9 330μF/35V 1 1 CX1 CY1 1 D1 2 1 D2,D4 D3 22nF/275V 2.2nF MBRS3200 T3G BAV21W S1ML 1 F1 250V/2A Inductor,1.5 mH ISU04N65A 1 1 1 1 1 1 1 1 1 1 1 1 L1,L2, l3 Q1 R1,R2 ,R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 1 RV1 1 T1 RM6 1 1 U1 NTC MP4027 220kΩ 3 1 3 5.1kΩ 470k 5.23kΩ 1MΩ 43kΩ 20Ω 2.2kΩ 9.53kΩ 1.8Ω 1.1Ω 30kΩ 100kΩ 100Ω TVR10431K SY Ceramic Cap,C0G,50V CBB, 104/400V Ceramic Cap,X7R,50V Ceramic Cap,X7R,50V Ceramic Cap,X7R,10V Ceramic Cap,X7R,630V Ceramic Cap,X7R,50V Electrolytic Capacitor;35V; Electrolytic X Capacitor,275V Y Capacitor,4000V 0603 DIP 1206 0603 0603 Manufacturer Taiwan Semiconductor murata Panasonic murata TDK murata 1206 TDK C3216X7R2J223K 0603 TDK C1608X7R1H222K DIP Jianghai DIP DIP PX223K3IB19L270D9R JNK12E222MY02N Diodes,200V,3A SMB Caili Hongke ON Semiconductor Diodes Diodes COOPER BUSSMANN Diodes,200V,0.2A Diodes,1000V,1A Package SOIC-4 SOD-123 SMA Manufactuer_P/N MB6S GRM1885C1H100JA01 CBB 0.1μF/400V GRM31CR71H475KA12L C1608X7R1H222K GRM188R71A105KA61D CD263-35V330 MBRS3200T3G BAV21W-7-F Taiwan Semiconductor SS-5-2A DIP Inductor,15mH/0.21A DIP TDK TSL0808RRA-152KR21 650V/4A TO-251 IPS ISU04N65A RES,1% 1206 Yageo DIP,0.5W RESISTOR Film RES, 1% DIP,0.25W RESISTOR Film RES,1% Film RES, 1% Film RES, 1% Film RES, 1% RES, 1% Film RES, 1% Film RES, 1% Film RES,5% Film RES, 1% DIP 0603 DIP 0603 0603 0603 0603 1206 1206 1206 1206 1206 any Yageo any LION Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo 430V/2500A DIP TKS TVR10431KSY RM6 EMEI FX0314 FCTSOT-8 0603 MPS murata RM6, Np:Ns:Naux=115:23:26 , Lp=2.18mH LED Lighting Controller NTC Thermistor SS-5-2A RC1206FR-075K1L RC0603FR-075K23L RC0603FR-0743KL RC0603FR-0720RL RC0603FR-072K2L RC0603FR-079K53L RC1206FR-071R8L RC1206FR-071R1L RC1206FR-0730KL RM12JTN104 RC1206FR-07100RL MP4027GJ-Z NCP18WM224E03RB EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 5 EV4027-J-00A– EVB DESCRIPTION TRANSFORMER SPECIFICATION Electrical Diagram RM6 1 N4 Pri. 57Ts Φ0.17mm NC1 N1 Pri. W1 23Ts Φ0.30mm T.I.W B1 58Ts Φ0.17mm 2 6 N2 Bias N3 Sec. 26Ts Φ0.14mm AUX+1 6 E2: 0.025mm×6mm Winding Start Figure 4 – Transformer Electrical Diagram Notes: 1. Don’t connect NC, AUX+, W and B to any pin of Bobbin. 2. E is a copper adhered to the core’s periphery, and connected to pin6. Winding Diagram Pin. Side Top. Side 3Ts 1Ts N4 N3 1Ts 1Ts N2 N1 Bobbin Figure 5 – Winding Diagram EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 6 EV4027-J-00A– EVB DESCRIPTION Winding Order Winding No. N1 N2 N3 N4 Tape Layer Number 1 1 1 3 Start & End 2→NC AUX+→6 W→B NC→1 Magnet WireΦ(mm) 0.17 0.14 0.30 (T.I.W) 0.17 Turns 58 26 23 57 Electrical Specifications Electrical Strength Primary Inductance Primary Leakage Inductance 2 seconds, 60Hz, from Pins 1, 2, 6, AUX+ to W, B Pins 1- 2, all other windings open, measured at 50kHz, 0.1 VRMS Pins 1-2 with pins 6, AUX+ W, B shorted, measured at 60kHz, 0.1 VRMS 3000VAC 2.18mH±8% 20μH±10% Materials Item 1 2 3 4 5 6 7 8 9 10 Description 2 Core: RM6, UI=2500±25%, AL=184.5H/N ±3% GAP, ACME P4 or equivalent Bobbin: RM6, 3+3PIN RMMOVE PIN6 1SECT TH, PM9630 UL94V-0 Wire: Φ0.17mm, Φ0.14mm, 2UEW, CLASS B or equivalent Triple Insulation Wire: Φ0.30mm,TRW(B) or equivalent Tape: 6.5mm(W)×0.06mm(TH) Tape: 7.0mm(W)×0.06mm(TH) Copper: 6.0mm(W)×0.025mm(TH) Varnish: JOHN C. DOLPH CO, BC-346A or equivalent Adhesive: 400-36 or equivalent Solder Bar: CHEN NAN: SN99.5/Cu0.5 or equivalent EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 7 EV4027-J-00A– EVB DESCRIPTION EVB TEST RESULTS Performance Data VIN(VAC) PIN(W) Vo(V) I6LEDs(A) Po(W) Efficiency PF I5LEDs(A) I4LEDs(A) I3LEDs(A) 90 100 110 120 135 150 170 185 200 220 230 240 250 265 7.89 7.81 7.79 7.76 7.74 7.72 7.71 7.73 7.75 7.79 7.81 7.86 7.88 7.95 19.45 19.44 19.44 19.44 19.44 19.44 19.44 19.44 19.44 19.44 19.44 19.44 19.43 19.43 0.344 0.344 0.344 0.344 0.345 0.345 0.345 0.345 0.345 0.345 0.345 0.345 0.346 0.346 6.69 6.69 6.69 6.69 6.71 6.71 6.71 6.71 6.71 6.71 6.71 6.71 6.72 6.72 84.80% 85.63% 85.85% 86.18% 86.65% 86.88% 86.99% 86.76% 86.54% 86.09% 85.87% 85.33% 85.31% 84.56% 0.987 0.987 0.985 0.982 0.977 0.971 0.961 0.953 0.945 0.931 0.922 0.914 0.906 0.901 0.347 0.347 0.347 0.348 0.348 0.348 0.348 0.349 0.349 0.349 0.349 0.349 0.35 0.35 0.35 0.351 0.351 0.351 0.351 0.351 0.352 0.352 0.353 0.353 0.353 0.353 0.353 0.354 0.354 0.354 0.355 0.355 0.355 0.355 0.356 0.356 0.357 0.357 0.356 0.358 0.358 0.358 Harmonic Data The design passes EN6100-3-2 Class C requirement. 110V Harmonic Order Limit (Active input power <25W) Content mA 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 57.12 31.92 16.80 8.40 5.88 4.98 4.31 3.80 3.40 3.08 2.81 2.59 2.40 2.23 2.09 1.96 1.85 1.75 1.66 72.31 9.74 1.99 0.63 1.02 1.12 1.06 0.92 0.73 0.50 0.28 0.07 0.13 0.28 0.39 0.45 0.48 0.45 0.42 0.32 Test Result (Pass/Fail) Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass 230V Harmonic Order Limit (Active input power <25W) 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 28.80 16.09 8.47 4.24 2.96 2.51 2.17 1.92 1.72 1.55 1.42 1.30 1.21 1.12 1.05 0.99 0.93 0.88 0.84 mA Content Test Result (Pass/Fail) 36.42 7.57 2.56 1.22 0.76 0.64 0.56 0.51 0.43 0.34 0.28 0.22 0.18 0.14 0.17 0.20 0.20 0.22 0.24 0.23 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 8 EV4027-J-00A– 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 EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 9 EV4027-J-00A– EVB DESCRIPTION EVB TEST RESULTS Performance waveforms are tested on the evaluation board. 6 LEDs in series, ILED=350mA, VOUT=20V, LP=2.18mH, Np:NS:NAUX =115:23:26. EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 10 EV4027-J-00A– EVB DESCRIPTION EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. 6 LEDs in series, ILED=350mA, VOUT=20V, LP=2.18mH, NP:NS:NAUX =115:23:26. EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 11 EV4027-J-00A– EVB DESCRIPTION EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. 6 LEDs in series, ILED=350mA, VOUT=20V, LP=2.18mH, NP:NS:NAUX =115:23:26. EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 12 EV4027-J-00A– 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. 6. For PWM dimming demo, remove NTC thermistor and C7, apply a >200Hz PWM dimming signal on NTC pin, make sure the PWM signal has same GND with primary circuit GND. 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. EV4027-J-00A Rev. 1.1 www.MonolithicPower.com 9/9/2013 MPS Proprietary Information. Patent Protected. Unauthorized Photocopy and Duplication Prohibited. © 2013 MPS. All Rights Reserved. 13